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Magnet Development Infrastructure

Director’s Review of the Fermilab High Field Superconducting Magnet Program. Magnet Development Infrastructure. Fred Nobrega January 31, 2006. Introduction Present capabilities Future capabilities Conclusions. Introduction.

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Magnet Development Infrastructure

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  1. Director’s Review of the Fermilab High Field Superconducting Magnet Program Magnet Development Infrastructure Fred Nobrega January 31, 2006 • Introduction • Present capabilities • Future capabilities • Conclusions

  2. Introduction • Superconducting magnet research and development has traditionally been one of the primary functions of the Fermilab Technical Division. • The infrastructure available for magnet development in TD has increased continually from the Tevatron magnet production days to the present. • The current infrastructure upgrades, directed toward a new generation of accelerator magnets, build on that rich history. Magnet Development Infrastructure

  3. Industrial Building 3 Magnet Development Infrastructure

  4. Cable R&D Lab Has the capability of : • Making LARP cable for quads (TQ’s & LQ’S) • Nb3Sn cable for high field cos theta & racetrack magnets. • NbTi & Copper-only cable for stabilizers and splices in high field magnets. • R & D Cable for high field magnets. A cable manufacturing machine, obtained from IHEP, is operated in IB#3. It has the capability of making 42 strand cable. Magnet Development Infrastructure

  5. Cable Insulation & Coil Winding Stations The cable insulating line and short coil winding stations have been used in IB3 for all short models since the Tevatron. Cable Insulating Line Coil Winding Station. 2 exist in IB3. Magnet Development Infrastructure

  6. Reaction Ovens R&D Reaction Ovens for Strand & Cable Programmable Reaction Oven for Short Coils Magnet Development Infrastructure

  7. Quadrupole Collaring Press • Quadrupole collaring press in IB3 was used for Tevatron quads and LHC IR Quad 1m models & Nb3Sn mech models. • Will be used to build a collar design Nb3Sn short (TQ) & long (LQ) quadrupole. Magnet Development Infrastructure

  8. Yoke and Skin Press • Currently used for HFDA short models • The press has previously been used for collaring and yoking of SSC Dipole short models. Quad Yoke Press for Short Models Magnet Development Infrastructure

  9. Vacuum Oven in IB2 • Currently used for SR, HFD and TQ high field magnets. • Large oven for epoxy impregnation of coils. • Oven is large enough for 6 meter long magnets. 2m O.D. x 8m, t = 60° C, pressure 30 m Hg Magnet Development Infrastructure

  10. Coil Curing Oven in IB2 • Currently used for SR, HFD and TQ high field magnets. • Large oven for curing epoxy of the coils. • Oven is large enough for 6 meter long magnets. 1.5m x 1m x 7.7m, t = 125° C, pressure is 1 atm Magnet Development Infrastructure

  11. Superconducting R&D Lab Short Sample Test Facility for SC strand and cable characterization. Magnet Development Infrastructure

  12. Instron • Large & small Instron machines • Provide wide range of test load capability • Material testing in tension and compression Instron 8503 & 4411 Materials Testing Machine Magnet Development Infrastructure

  13. Microscopy Lab • Used for the analysis of Nb3Sn strand and cable after reaction • SEM with a resolution of 3.0 nm. • Optical microscope JEOL Scanning Electron Microscope Magnet Development Infrastructure

  14. Industrial Center Building ICB is currently being used to build LHC IR Quads. It includes winding tooling, curing presses, collaring presses, and a yoke press, all with 6 m long capabilities. Tooling and presses used for cold mass fabrication are scheduled to move to IB3 this year. Magnet Development Infrastructure

  15. Long Coil Winding, ICB • Programmable long coil winder produces uniform and repeatable coils. Long Coil Winding Machine Magnet Development Infrastructure

  16. Long Coil Curing, ICB • Curing press is used to set the coil size for reaction, as well as allow the coils to be easily handled. Magnet Development Infrastructure

  17. Coil Measuring, ICB • Automatic azimuthal coil size measurements Magnet Development Infrastructure

  18. Shell Welding Press, ICB • Long yoke press with automatic linear welding capability Magnet Development Infrastructure

  19. Other Tooling In addition to the traditional pieces of equipment, many other types of tooling are available. Lifting fixtures, roll-over tables, and devices for manipulating coils and magnets will be used. Lifting Devices Rollover Fixture Magnet Development Infrastructure

  20. Design Specific Winding Tooling Fermilab has design-specific tooling for several coil sizes: • Available winding mandrels: • 43 mm dia (from HFDA Dipole coils) • 70 mm dia (from LHC IR Quad inner coils) • 90 mm dia (made for LARP quadrupole) • 102 mm dia (from LHC IR Quad outer coils) EDM’d Blocks Key inserts Strongback Magnet Development Infrastructure

  21. Design Specific Curing Tooling • Available Curing Molds (short & long): • 104 mm inside dia (used for HFDA Dipole coils and LHC IR Quad inner coils) • 136 mm inside dia (used for LARP Quad coils and LHC IR Quad outer coils) More details on how this tooling will be used is in Giorgio’s talk, “Nb3Sn Technology Scale-up”. Shim Blocks Precision laminated mold cavity Electric Heaters EDM’d End Plate Magnet Development Infrastructure

  22. Future Capabilities • The objective: • is to establish an infrastructure for the scale up of Nb3Sn magnets • The Results: • will enable LARP & core program long magnet fabrication capabilities • allows for future LHC quadrupole production possibilities Magnet Development Infrastructure

  23. IB3 Fabrication Floor Layout 1m Winder Short Curing Press Collaring Press Cable Insulation Line 6m Winder 6m Oven 2m-4m Winder Shell Welding Press Curing Press R&D Ovens SC Cable Lab Instron Lab Techs Office SEM Magnet Development Infrastructure

  24. Long Reaction Oven Procurement • One of 2 modules for 6m long oven • Photo taken at L&L Special Furnace Co. 1/12/06 • Qualification test at Fermilab ~ 1st week in April, 2006 Magnet Development Infrastructure

  25. Backup Generator • 100 kW backup generator • Used for ovens in case of a power failure during coil reaction Magnet Development Infrastructure

  26. Schedule Milestones • Complete commission of 6m oven, May 2006 • Start 2m dipole mirror winding, April 2006 • Start 4m dipole mirror winding, Sep 2006 • Complete ICB tooling move to IB3, Dec 2006 Magnet Development Infrastructure

  27. Conclusions • Technical Division at Fermilab has a world class magnet R&D infrastructure & will soon have the capabilities to make Nb3Sn coils up to 6m long. • Large investments in tooling, both generic and design-specific, were made to develop and build superconducting magnets. • This infrastructure is a key element for the success within LARP and other magnet R&D programs. • Technical Division has the tooling and personnel required to build and test magnets, as well as do R&D on cable and strands of various materials and configurations. Magnet Development Infrastructure

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