S. Caspi, LBNL

HQS Progress Report High Field Nb3Sn Quadrupole Magnet

Shlomo Caspi

LBNL

Collaboration Meeting – CM11 FNAL

October 27-28, 2008

S. Caspi, LBNL

Introduction

2

Collaboration :

• BNL – reaction and potting tooling

• FNAL – magnetic design, Islands, wedges, “end” spacers

• LBNL – cable, winding & curing tooling, mechanical design, magnet assembly.

Outline :

- Magnetic design

- Mechanical design

- Tooling design.

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Magnetics

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Coil cross-section and parameters

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Courtesy of V. Kashikhin

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Iron saturation & field quality - Roxie

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120 T/m

Courtesy of V. Kashikhin

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3D analysis - Tosca

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Courtesy of V. Kashikhin

Bpend/Bp

cen = 0.993

Iro

n p

ad

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Field, Gradient, Stored-energy - Poisson

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1.9 K / 4.4 K Layer 1 Layer 2

A/mm^2 2000 2500 3000 2000 2500 3000

Imax (kA) 17.5/15.98 18.58/16.95 19.4519.45/17.72 18.14 19.30 20.22

Bmax (T) 13.72/12.59 14.52/13.3 15.1715.17/13.9 13.55 14.34 14.98

Gmax (T/m) 197/181 208/191 219219/199

Short-sample straight section

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Mechanics

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HQS – Mechanical Shell based Structure

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570 mm outer diameter

Components

- Aluminum bolted collars => alignment

-remains in compression from assembly to operating conditions

- Iron pads and yoke

- Iron master key => alignment

- axial rods => axial preload

- 25 mm aluminum shell => azimuthal preload

- Coil and collar in compression

- Cooling area

Assembly

- 60 mm bladders located outside the key span

- 38 MPa pressure (600 + 50 microns clearance for 220 T/m)

- Collars, pads and key locations optimize to minimize stress

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HQ – CAD Model

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Gap keys slotBolted collars

Iron padsBladder location

Al shell

Iron master key

Loading keys slot

Iron yoke

Pole key

Courtesy of D. Cheng

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Design Concept and Guidelines

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• Use modified pads and collars for coil alignment– Collars for azimuthal alignment (Collars for azimuthal alignment (not for pre-stressnot for pre-stress))– Bolted pads for coils assemblyBolted pads for coils assembly– Keys, bladders and Aluminum shell during final azimuthal assemblyKeys, bladders and Aluminum shell during final azimuthal assembly– Axial rods to control axial forcesAxial rods to control axial forces

• Final pre-stress during cool-down by a shell based Aluminum structure

• Maintain full azimuthal contact between coil-island and island-collar– Bladder and key locations optimized

• Structure to maintain pre-stress up to expected “short-sample”

but coil pre-stress can be reduced if adjusted to the operating point.

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HQ – Mechanical analysisAzimuthal stress in the coil

13

Target

219 T/m

During bladder operation

-90 MPa

With loading key

-82 MPa

At 1.9 K -177 MPa

With Lorentz forces

-177 / 20 MPa -177 MPa

=> High but acceptable stress at short sample

-177 MPa

- 80 MPa

-82 MPa

- 20 MPa

-90 MPa

Courtesy of H. Felice

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Layer 1Layer 2Alignment key in the pole

G10 sheet

Aluminum bolted collar

Bolted at the pole against the pole key

Pads

Iron in the straight section

Stainless steel in the end

Iron masters

Iron yoke

Aluminum Shell

Axial Aluminum rods

Bolted to a Nitronic endplate

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Winding-Curing-Reaction-Potting

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HQ – Cable optimization

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Test winding samples

Variation of the keystone angle, thickness…

Up to now, 8 cables evaluated

Micrographs analyzed for each sample

- Edge deformation – strand distortion

- Deformation of the sub-elements

- Barrier

- Size of the facets on the surface of the cable

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HQ – Winding tests

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114 mm aperture mandrel 134 mm aperture mandrel

EDM part return end Rapid Prototype (RP) part lead end

=> 120 mm cross-section: minimum pole width 23.8 mm

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Winding tooling

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Winding layer 1

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Layer 2 spacer

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Curing layer 1

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Winding layer 2

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Curing layer 2

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Reaction tooling

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HQ Schedule (updated 9/18/08)

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ID Task Name

1 Coil Design2 Cable design & test winding3 Coil design4 Tooling, Parts, Practice Coils5 Winding/Curing Tooling Design6 Winding/Curing Tooling Procure7 Coil parts design8 Coil parts procurement9 Practice winding #110 Practice winding #211 Reaction/potting tooling design12 Reaction/potting tooling procure13 Practice reaction/potting #114 Practice reaction/potting #215 Structure Design and Fabrication 16 Mechanical Design Concept17 Mechanical Analysis18 Engineering Design19 Structure Procurement20 Mechanical model21 HQ01 Model22 Cable and coil parts23 Coil Wind / Cure24 Coil React25 Coil Impreg26 Magnet Assembly27 Test28 Analysis & Reporting29 Review 12/7

Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec JanQ1 '08 Q2 '08 Q3 '08 Q4 '08 Q1 '09 Q2 '09 Q3 '09 Q4 '09 Q1 '10 Q2 '10

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Summary

• We have 90m of cable to wind first practice coil

• Design of coils, spacers, end-shoes, layer-to-layer transition completed.

• Shipment of tooling for winding and curing in the next few weeks

• Reaction and potting tooling in final design stage.

• 3D magnetic design completed.

• 3D analysis of structure and assembly underway.