SMC Design overview of the construction and project issues

SMC Design overview of the

construction and project issuesJ.C. Perez

on behalf of SMC collaboration team

M. Bajko, B. Bordini, S. Canfer, G. Ellwood, J. Feuvrier, M. Guinchard, M. Karppinen

C. Kokkinos, P. Manil, A. Milanese, L. Oberli, F. Regis, G. De Rijk

EUCARD-WP7-HFM Short Model Coil review

12 December 2011

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OUTLINE IntroductionWhat’s SMC?FEM modelsSMC coils and structureManufacturing steps and magnet assemblySMC#1 coils fabrication and cold powering tests

resultsSMC#2 coils fabricationSMC#3_a coils fabrication and cold powering

tests resultsSMC#3_b coils fabrication Conclusion

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J.C. Perez / TE-MSC-MDT

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INTRODUCTION

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◦ The SMC project started in 2007 as a CERN-CEA-RAL-LBNL collaboration (NED 1.5)

◦ SMC is a way to test Nb3Sn cables in a small racetrack magnet and reach 12 T on the cable

◦ SMC is a modified version of the subscale magnet of LBNL

◦ SMC has been used to cross-check results using different codes formulations(CAST3M, ANSYS, ROXIE, Vector fields OPERA)

◦ Several coil configurations have been produced in the different laboratories and cold tested in a common structure at CERN


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WHAT’s SMC?1

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SMC is a tool to learn and test :

Technologies needed for a Nb3Sn based high field magnet fabrication:

• Cable insulation• Coil reaction• Coil impregnation• Trace fabrication• Bladder fabrication Techniques of coil fabrication and magnet assembly• Winding • Coil instrumentation and Protection• Structure instrumentation• Magnet assembly with bladders and keys• Nb3Sn/Nb-Ti cable connection

SMC is a tool to qualify: Nb3Sn cables in a real magnet configuration

SMC is the “STEP 0” to build a Nb3Sn accelerator magnet at CERN


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FEM Models

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CATIAANSYS Design Modeler

ANSYS Mechanical

Assembly Design

Geometry Design

Contact Regions

Meshing Process

Parametric Coil Block

Courtesy of C. Kokkinos

See more details in the presentation made by C. Kokkinos


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SMC Coils1

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• Double pancake race-track coil configuration

• High field zone located in the straight part of the central island thanks to the presence of end-spacers

• Titanium spacers & end-saddles• Nb3Sn/NbTi splice integrated in the

end-saddle connection side• Instrumented with Vtaps and stain

gauges using dedicated printed circuits (“Traces”)


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SMC Structure

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KeysYoke

Shell

Bladders

Coil packCoil pads

Rods


SMC configuration

Coil pack and Iron yoke mounted in the

instrumented Al2219 T851 shell

8J.C. Perez / TE-MSC-MDT1

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Iron yoke

Vertical key

Lateral pad

Vertical pad Longitudinal rods

Longitudinal compressing system for the rods

Racetrack coil

Manufacturing steps1

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9J.C. Perez / TE-MSC-MDT

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SMC assembly 1

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Assembly Parts

Coils & Rods Shell & Yoke Pads Bladders

KeysShims

Assembly Overview

Keys insertion Electrical connectionsJ.C. Perez / TE-MSC-MDT

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SMC#1coil fabrication

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2 double pancakes wound @ CERN in collaboration with RAL using “Low performance” cable (14 x Ø1.25 mm Alstom IT with low Jc from NED)

Cables insulated with S2-Glass tape wrapped with 50% overlap Coils reacted @ RAL in TWO different furnaces and reaction tooling Coils instrumented and potted @ RAL in collaboration with CERN using TWO

different moulds Coils fabrication dates:

Coil #1 made in November 2009. Coil #2 made in March 2010

Cold test 1: Magnet limited to 3915 A. Quench detected in one Nb3Sn/NbTi splice of coil# 2 : 40 nOhms contact

resistance measured Cold test 2: Single coil powering configuration using coil #1.

Only one quench detected in layer 1

All other quenches detected in layer 2 and never in the splice area


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SMC#1: Cold Powering Tests

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0 2 4 6 8 10 12 14 16 180

2000

4000

6000

8000

10000

12000

14000

16000

SMC1 Powering Tests (One coil configuration)

@ 4.2K @ 1.9KShort Sample limit

Quench Nr

I (A

)

0 1 2 3 4 5 6 7 8 9 10 11 12 13 140

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

SMC1 one coil

SMC1 two coils

strand 4.2 K

B peak coil [T]

I [A

]

Courtesy of A. MilaneseJ.C. Perez / TE-MSC-MDT

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SMC#2 coil fabrication @ CEA

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One coils wound with PIT EAS 14 x Ø1.25 mm strand Cable insulation made of 2 layers of Hiltex S2-Glass tape +

ceramic precursor (CEA formulation) Cable wrapped at CERN in June 2010 First coil wound at CEA in July 2010

Impregnation Setup

Insulated cable

Winding operationCoils not assembled in the structure, not cold tested.

Coils fabrication stopped in June 2011 at the CSP (Comite Suivi Protocol) of the Exceptional French Contribution. See detailed presentation by F. Rondeaux J.C. Perez / TE-MSC-

MDT

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SMC#3_a coils fabrication @ CERN • 2 coils for SMC3 with PIT 14 x Ø1.25 mm strand with Ti-

islands and spacers wound in November 2010• Cable insulated with S2-Glass sleeve (FNAL type)• Electrical insulation of the central island on the layer

jump area with ceramic 989F • Heat treatment in a vacuum furnace @ CERN• Coils potted using Epoxy NY 750 & Jeffamine D-400 • Electrical problems, no longitudinal pre-load • Magnet assembled in May 2011• 1st assembly: 2 runs of cold powering tests performed in

the new vertical test station (SM18) in June and September 2011

• 2nd : reloading to increase pre-stress on coils and magnet retested in December 2011

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SMC#3_a Assembly Configuration

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Shell-Azim.strain [μm/m] Coil-Normal stress σx (MidPlane) [Mpa]

Coil-VM stress (MidPlane) [Mpa]

Initial strain

value @ 0,3_Theta

@300K @4.2K @Iss

@300K @4.2K @Iss

@300K @4.2K @Iss

500 500 1320 1275 -47 -133 -126 37 125 153

340 340 1196 1228 -34 -123 -116 24 114 140

673 673 1598 1608 -69 -147 -147 47 137 164

SMC3 1st test

run June 2011

SMC3 Reload and 3rd test run

November 2011

SMC3 2nd test

run 2011

VK 1(mm)

VK 2(mm)

VK 3(mm)

VK 4(mm)

HK 1(mm)

HK 2(mm)

Rod 1(µm/m)

Rod 2(µm/m)

Shell_0_T(µm/m)

Shell_3_T(µm/m)

6.65 6.9 6.5 6.8 10.5 10.5 82 44 541 477

FINAL CONDITION @ 293 K – SMC3 June 2011

VK 1(mm)

VK 2(mm)

VK 3(mm)

VK 4(mm)

HK 1(mm)

HK 2(mm)

Rod 1(µm/m)

Rod 2(µm/m)

Shell_0_T(µm/m)

Shell_3_T(µm/m)

6.65 6.8 6.5 6.8 11 10.7 55 32 706 648

FINAL CONDITION @ 293 K – SMC3_ November 2011


See detailed presentation by Ch. Kokkinos

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 10010000

11000

12000

13000

14000

15000

16000

Run 3 with higher pre-stress

Run 1 Run 2 after thermal cycle

12.82 T

13.92 T

SMC#3 Training

@ 1.9 K

@ 4.2 K

Iss@ 1.9 K( opera 3D)

Iss@ 4.3 K( opera 3D)

Quench history

Qu

en

ch c

urr

en

t, I

q [

A]

85 % Iss @4.2K74 % Iss @4.2K

95 % Iss @4.2K

91 % Iss @1.9K

SMC#3_a cold tests results

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See detailed presentation by M. Bajko

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SMC#3_b coils fabrication status and program

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• Status • 2 coils for SMC3_b using PIT 14 x Ø1.25 mm strand

with Ti-islands and spacers wound in September 2011• Electrical insulation of the central island and spacers

with Al2O3 plasma spray coating

• Cable insulated with S2-Glass sleeve (FNAL type)

• Plan• Heat treatment on Argon atmosfere furnace @ CERN• Coils to be potted using Epoxy NY 750 & Jeffamine D-

400 • Magnet assembly scheduled Q1-2012


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Conclusions 7 SMC coils have been produced until today 2 SMCs : SMC#1 and SMC# 3 have been completely assembled

and cold tested 2 types of Nb3Sn cables (IT and PIT) have been used 2 types of insulation techniques, tape and sleeve, have been

tried Bladder design and production have been qualified The impregnation method, using an open mold, shows good

results for this type of coils Lessons learned during SMC#1 fabrication and applied for

SMC#3 improved significantly the magnet performance The excellent results obtained with SMC#3_a assembly must be

confirmed on SMC#3_b where we seek to repeat performance and eliminate electrical problems between coils and spacers

The SMC project is a perfect example of efficient collaboration between different teams and laboratories

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Thanks for your attention !!

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3D view of SMC model

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SMC Design overview of the construction and project issues

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