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Chamber & Vacuum System

Chamber & Vacuum System. Dean R. Walters Soon-Hong Lee, James Bailey, James Morgan, Dana Capatina , Scott Doran, ANL Lou Ann Tung, LLNL. X-Adjustor. Z-Adjustor. Support Assembly. Production Vacuum Chamber Ass’y. Vacuum Chamber Assembly.

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Chamber & Vacuum System

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  1. Chamber & Vacuum System Dean R. Walters Soon-Hong Lee, James Bailey, James Morgan, Dana Capatina, Scott Doran, ANL Lou Ann Tung, LLNL

  2. X-Adjustor Z-Adjustor Support Assembly Production Vacuum Chamber Ass’y Vacuum Chamber Assembly

  3. Measurement results of magnetic permeability (r) • Anneal conditions • Vacuum pressure at 1.0 x 10-4 Torr • 1,750 º F for 30 minute soaking on 20Cb-3 and 1,950 º F for 30 minute soaking on the other types • Rapid Nitrogen gas quenching • 316LN had stable permeability values of less than 1.010, even if cold-works and welding. • 310S and Nitronic 40 had increased in permeability after welding significantly. • 20Cb-3 had acceptable permeability values less than 1.020 (most less than 1.010) and good welding characteristics (less heat-affected zone) • Nitronic 33 and 20Cb-3 had increased in permeability after annealing.

  4. B/B < 1.5 x10-4 8.0 mm Hall probe holder Measurementsof the changes of applied magnetic fields • Sample chambers under APS undulator "A" • A 3-inch-long sample vacuum chamber was inserted Into a hybrid permanent magnet undulator with a 3.3 cm period and 8 mm min. gap • To Investigate high magnetic field influence to the relative magnetic permeability • Peak of applied magnetic field: ~ 1.2 T Undulator A Sample chamber

  5. Fabrication Processes SST Sheets (144” x .75” x .120”) 316LN SST SST Plate, End Cap (144” x 7.5” x 1”)(144” x .5” x.25”) 20Cb-3 Polishing/Milling Milling/Polishing Seam Welding Final Machining Cleaning/Baking Coating

  6. NW 50 Flange -Clamp Type (316L SST) Compound screws (Brass Screws & SST ) Vacuum Chamber Chamber Strong-back (316 SST) Chamber Strong-back (20Cb-3) Top & Bottom Strips (20Cb-3) Top & Bottom Strips (316LN) End Cap (20Cb-3) End Cap (20Cb-3) Prototype Vacuum Chambers Prototype A Prototype B

  7. SUT Machining Results • Material: Austenite stainless steel 316 • Supplier: Walco Tool & Engineering • Parallelism of chamber surfaces (0.100 mm): 0.250 mm • Thickness of chamber (6.00 ~ 6.08 mm) : max. 6.15 mm • Straightness of chamber edge (± 0.200 mm) : max. 0.406mm bowed • Vibratory or thermal stress relief is required, which may restore the original properties of the base metal E H

  8. Prototype B Machining Results • Material: Austenite stainless steel 316 • Supplier: Dial Machine Inc. (measured Aug. 8, 06) • No attempt was made to tweak in, or adjust, the constrained condition to improve the results. • Flatness of nose bottom surface in the clamped condition (0.100mm): 0.314mm • Parallelism of nose bottom surface to strongback bottom in the clamped condition (0.100mm): 0.198 mm • Parallelism of nose top surface to nose bottom surface in the clamped condition (0.100mm): 0.107 mm • Straightness of chamber edge (180.0± 0.20mm) : 179.54~179.70mm (0.160mm bowed) • Thickness of chamber every 12” in the clamped condition (5.0±.08mm) : 4.945~5.112mm • Flatness of the surface of machining fixture in the strongback clamped condition: 0.04mm • Flatness of the bottom surface of strongback in the free state: 1.143mm

  9. Polishing of Stainless Steel • Samples of True #8 stainless steel sheets from Pacific Plus Inc. of Dallas, TX / Hwa Yang Stainless Steel Group in China. • True #8 and super #8 are trademarks of Pacific Plus International, Inc. • 1.5 mm thick 316 SST sheets (1 ft x ft) and 0.5 mm thick 304 SST sheet (4 ft x 8 ft) were bought to evaluate the impact of manufacturing operation on the surface finish. • Samples were polished at Fine Art Inc. and Polished Metals Limited. • Measurements • Used Tencor Alpha-Step to obtain a 2D surface profile. • Used MicroXAM RTS surface profiler (White light interferometry) MicroXAM RTS from www.ade.com

  10. WLI Sample: #PLM 2 Mode: PM Objective: 50x Size: 0.244 x 0.244 mm2 r(z): -1867 mm; hrms: 27.9 nm # 8 x’rms: 14.4 mrad; z’rms: 3.6 mrad Sampled Data (1024x1024) Lineout (x: #200; z: #300-#400) Full Spectrum (1024x1024) Sample: #PLM 2 Size: 0.130 x 0.130 mm2 AFM r(z): -907 mm; hrms: 13.5 nm x’rms: 24.4 mrad; z’rms: 8.2 mrad Sampled Data (500x500) Lineout (x: #200; z: #300-#400) Full Spectrum (500x500) Evaluation of Roughness Scans - Polished For wakefield considerations, the beam- (or z-) direction is the most important and all measurement results are within tolerance, i.e., have rms derivatives in z of less than 10 mrad.

  11. CO2 Laser Weld PrototypingInspection Results for Sample 3 Intermittent weld Seal weld Groove

  12. CO2 Laser Weld Prototyping42” Vacuum Chamber Prototype Fixturing for end cap welding Fixturing for strong back welding Welding strong back Welding end cap

  13. Final Machining Prototyping Machined to red line both sides Vacuum Chamber Gap Actual Weldment

  14. Final Machining Prototyping Preliminary Inspection Results for the 42” Prototype • <0.002” Flatness & <0.002” Tolerance on Thickness

  15. Coating Basics

  16. Test set up operating Coating inside a 7.9 mm Glass tube Coating inside a 12.7 mm Glass tube

  17. Prototype Development May Apr. May June July Aug. Sept. Oct. Nov. Dec. Jan. Feb. 2006 2007 42” Prototype Parts Proc. 304 SS & Mach. Fixtures (Weld) Design & Fab. Assembly Weld Mach Coat Laser Weld Development 6” Samples YAG @ ANL 18” Samples CO2 @ Vendors Final Mach. Development 6” Samples Mach. @ ANL Design & Fab. Fixtures (Mach)

  18. May Apr. May June July Aug. Sept. Oct. Nov. Dec. Jan. Feb. 2006 2007 Mach/ Coat Mach/ Coat Fab. Fix. & Weld Fab. Fix. & Weld Prototype Development Prototype A Strongbk. Strongbk. Strongbk. Strongbk. Strongbk. P.O. 20Cb-3 Mach. End Cap End Cap End Cap End Cap End Cap Proc. 20Cb-3 & Initial Mach. Side Walls Side Walls Side Walls Side Walls Side Walls Polish Sheet Intl. Mach. Weldment Weldment Weldment Weldment Weldment Prototype B Strongbk. P.O. Proc. 316 L & Initial Mach. End Cap Proc. 20Cb-3 & Initial Mach. Intl. Mach. Side Walls Polish Sheet Weldment

  19. Prototype Development May Apr. May June July Aug. Sept. Oct. Nov. Dec. Jan. Feb. 2006 2007 Coating Development Part #2 Consultant Agreement Place PO 1St Equipment Design Procure Assy Full Size Setup Power Supply Loan Agr Ship Install Process Dev Bench Test 42” Prt

  20. Chamber Schedule

  21. Chamber Design Review The LCLS undulator vacuum chamber and system were reviewed by a committee composed of John Grimmer, APS, Nadine Kurita, SLAC, Allan Rowe, FNAL, and John Noonan, ANL, chair on September 27 and 28, 2006 Schedule The schedule for fabrication and delivery of vacuum chambers for the undulator vacuum system is tight, especially for the undulator vacuum chamber. This is a complex part with stringent physics requirements, especially the surface finish. Aspects of the chamber are demonstrated, but a full-size prototype will not be complete until December, 2006. The Undulator Vacuum Chamber There are no technical barriers to fabrication of the chambers. However, there are tooling and detailed fabrication issues that need to be answered in order for production to proceed. Successful chamber fabrication will be a significant accomplishment. The physics are stringent Fabrication of the full size prototype chamber is essential and the engineers should have all the APS and LCLS support that they need to complete the fabrication. The full size prototype will determine vacuum integrity, outgassing rates for the chamber, coating surface finish, and dimensional straightness. It is important to perform a test in which the full size chamber is installed in an undulator and its straightness measured. The survey groups need to be involved in the tests and certify that the installation procedure is reasonable. Magnetic measurements need to be repeated on the 20Cb-3 steel. The 20Cb-3 material has no apparent pedigree in demanding vacuum and magnetic applications. The prototype has not yet been welded leak tight and will clearly be "worse" than 316LN in magnetic performance, although the effect of the difference is debatable.

  22. 6 Month Look Ahead • Prototypes • 42” Prototype Complete Nov. 20 • Full Length Prototype A Jan. 25 • Full Length Prototype B Jan. 20 • Production • First Lot Strongbacks Material Nov. 10 • First Lot Strongbacks Machining Jan. 19 • Side Wall Machining Jan. 10 • End Cap Machining Jan. 19 • First Lot Laser Welding Feb. 20 • First Lot Final Machining Mar. 16 • First Lot Vacuum Processing and Coating Mar. 30 • Second Lot Strongback Material Jan. 25 • Second Lot Strongback Machining Mar. 7

  23. Vacuum System Calculations • Mathematica model based on location increments of 1 cm long in order to determine the system pressure profiles.

  24. Vacuum System Calculations • In past hand vacuum calculations have been used to estimate the vacuum system performance • Recently a collaboration with LLNL has been established to provide calculations. • Below are the results obtained at this point. • The next analysis will include: -Add in the turbo and roughing pumps (with S(p)) in the long break and an ion pump in all three breaks -Put in the time-dependent outgassing rate for stainless steel (already have fit) -Put in the different rates for copper and aluminum

  25. Long break layout (Short break is the same but without the valve spool)

  26. Pressure profile with one ion pump on the long break with one undulator section Dz = 1 cm All surfaces outgas at 1.6 x 10-11 T-l/s/cm2 cm One undulator section Long break

  27. Conclusions • Chambers • This has not progressed as expected. The Strongback delay has rippled through the prototype schedule and it impacts the production schedule. • The Design Review Committee has agreed that the Strongback can enter production, but testing is needed on the full sized prototypes to continue with the production of the whole weldment. • These Prototypes must be done before the end of January so that the production units are not impacted.

  28. End

  29. CO2 Laser Weld Prototyping42” Vacuum Chamber Prototype Results in Constraint Condition 0.001” 0.002” -0.001” 0.000” 0.001” 0.000” 0.001” 0.000” 0.001” 0.000” 0.002” 0.000” 0.000” 0.000” 0.001” 0.001” Flatness Variation Along Center of Wall Sheet Across Sheet Flatness <0.001”

  30. Vacuum Chamber alignment Vertical Adjustment Screws (14)

  31. On Going Work • Test Set up • Cathode Guides • Straightening of Cathodes • Tensioning of Cathodes • Vertical positioning • 42” chamber • Full size setup • Vertical Coating Stand

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