Working Group MQXF Long Coil Fabrication Status and

Working Group MQXF Long Coil Fabrication Status and Plans at Fermilab Fred Nobrega Hi. Lumi - LARP Collaboration Meeting May 11 -13, 2015 FNAL

Outline • Overview • Fabrication Steps – Wind & Cure • Reverse cable bending – Reaction • 6 m furnace redo • Previous reaction cycles – Impregnation • Vacuum oven max temp 80 C • Wisconsin oven coil cure • Fabrication Plan • Summary Working Group MQXF Long Coil Fabrication May 13, 2015 2

Overview • • Practice cable 1 coil fab process at FNAL Practice cable 1 a coil fab process at BNL Long coil #2 mirror magnet assembly at FNAL Long coils #3 -6 1 st long magnet – All coil winding at FNAL – Coils 3 & 5, reaction & impregnation at BNL – Coils 4 & 6, reaction & impregnation at FNAL • Coil travelers updated and revised as needed. Working Group MQXF Long Coil Fabrication May 13, 2015 3

Fabrication Status, Wind & Cure • Long coil winding machine recently modernized and commissioned since last used in 2005 (ICB) for LHC IR Q 2 a/b coils. – Winding Machine designed for single layer coils, coil pairs spliced. • New curing mold complete & ready for introductory cure cycle. • All curing tooling is at FNAL, spacers, pushers, shells, etc. • Coil winding of 1 st practice coil with practice Nb 3 Sn cable has begun. Working Group MQXF Long Coil Fabrication May 13, 2015 4

Reverse Cable Bending • Reverse cable bending study results presented at last December’s MQXF Design Review to evaluate cable popped strands and cable stability in the ends using the Selva coil winder. • No popped strands were observed. Inspection of the cable SS cores were typical in appearance for both winding stations used. • An additional reverse bend occurs at the cable re-spool step that was not included in the study. SS Core 1 st Turn Comparison Selva SQXF (rotation table) Working Group MQXF Long Coil Fabrication May 13, 2015 5

Winding Setup Cable Re-spool Typical cable re-spool L 1 Boom wind direction, CW RE cable spool layer 1 Bridge boom cable spool layer 2 Cable clamped to layer 1 key LE W a l k w a y Layer 2 Spool Layer 1 Spool Selva cable re-spool Layer 2 Spool Layer 1 Spool Working Group MQXF Long Coil Fabrication May 13, 2015 6

Fabrication Status, Reaction/Impregnation • 2 sets of reaction and 2 sets of impregnation tooling were procured in Aug. • 100 % of form blocks received by FNAL – ~25% rejected and are being reworked or remade. • 4. 4 m long base plates and stiffener plates are 75% complete. – Two of each is expected at FNAL very soon. • Upon inspection approval, there will be 1 complete reaction tooling assembly and 1 complete impregnation assembly – Remaining 2 sets of plates expected in about 4 -6 weeks. – New/reworked form blocks expected in about 6 weeks. Working Group MQXF Long Coil Fabrication May 13, 2015 7

Coil LQ 05 Lead End Furnace Door Return End T/C 12 T/C 13 Witness samples argon exhaust T/C 9 T/C 1 argon T/C 14 T/C 10 T/C 15 argon inlet flow thru T/C 11 T/C 2 Working Group MQXF Long Coil Fabrication T/C 4 May 13, 2015 8

Coil LQ 05 Lead End Furnace Door Return End T/C 12 T/C 13 Witness samples argon exhaust T/C 9 T/C 1 argon T/C 14 T/C 10 T/C 15 argon inlet flow thru T/C 11 T/C 2 Working Group MQXF Long Coil Fabrication T/C 4 May 13, 2015 9

Reaction Furnace Overshoot • L&L Furnace will troubleshoot and re-balance the reaction furnace during week of May 26 -29. • Preliminary issue points to the PLC Programming. – The Set. Point Profiler had been reset during a reaction cycle. – Possible cause is a power outage for longer than 10 minutes. • Other possible issues include bad elements, fuses, bad PLC Card, etc. Working Group MQXF Long Coil Fabrication May 13, 2015 10

Coil Impregnation Process • • • Impregnation fixture connected to open reservoir at LE. Fixture inclined in vacuum furnace. Evacuated to 25 m. Torr. While under vacuum, bake at 55 C for 45 hours. add external heaters, reduce time Epoxy mixed and warmed to 55 C, degassed. Fill rate observed through glass tube. peristaltic pump When epoxy reaches reservoir the supply line is closed. Furnace let up to atmospheric pressure. Soak overnight at 60 C. Fixture then moved to curing oven. cure in vacuum furnace with external heaters Cure at 110 C for 5 hours then 125 C for 16 hours Working Group MQXF Long Coil Fabrication May 13, 2015 11

Fabrication Plan • • • Practice coil #1 5/4/15 - 11/25/15 Practice coil #1 a 6/30/15 - 12/10/15 Long coil #2 9/2/15 - 3/1/16 Long coils #3 -6 11/9/15 - 7/8/16 1 st long magnet assembly 10/3/16 - 2/10/17 Magnet test 2/27/17 - 5/19/17 Working Group MQXF Long Coil Fabrication May 13, 2015 12

Summary • Wind & Cure – Additional reverse cable bend during re-spooling. Long coil winding has begun. Impact if any unknown at this time. – Curing tooling is complete. • Reaction & Impregnation – Reaction furnace will be serviced in late May. – Reaction and impregnation tooling procurement is about 75% complete. – One complete set of reaction and impregnation tooling expected to available when the 1 st practice coil winding and curing is complete. • Coil travelers being updated/revised as needed. Working Group MQXF Long Coil Fabrication May 13, 2015 13

BACKUP SLIDES Working Group MQXF Long Coil Fabrication May 13, 2015 14

CERN’s 11 T Dipole Coil Winder Working Group MQXF Long Coil Fabrication May 13, 2015 15

CERN’s Coil Winder, L 2 Spool Holder Working Group MQXF Long Coil Fabrication May 13, 2015 16

Impregnation Working Group MQXF Long Coil Fabrication May 13, 2015 17