BNL FNAL LBNL SLAC Magnet Systems Status and

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BNL - FNAL - LBNL - SLAC Magnet Systems Status and Plans in view

BNL - FNAL - LBNL - SLAC Magnet Systems Status and Plans in view of the Chamonix Workshop discussions and the LHC Luminosity Task Force recommendations Gian. Luca Sabbi LARP Collaboration Meeting 14 FNAL, April 26, 2010 CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

Outline • Magnet R&D Program components • Recent technical progress Ø Long Quadrupoles Ø

Outline • Magnet R&D Program components • Recent technical progress Ø Long Quadrupoles Ø Model Quadrupoles Ø Materials • LARP plans in the new IR upgrade scenario Ø Near term (2010 -12) Ø Medium term (2012 -14) Ø From R&D to construction • Summary CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

Magnet R&D Program Components 1. Materials: • Strand specification and procurement • Cable fabrication,

Magnet R&D Program Components 1. Materials: • Strand specification and procurement • Cable fabrication, insulation and qualification • Heat treatment optimization Ongoing 2. Technology development with Racetrack Coils: • Subscale Quadrupole (SQ) • Long Racetrack (LR) Completed 3. Cos 2 q Quadrupoles with 90 mm aperture: • Technology Quadrupole (TQ) • Long Quadrupole (LQ) ~75% 4. Cos 2 q Quadrupoles with 120 mm aperture: • High-Field Quadrupole (HQ) CM 14, 4/26/2010 Magnet Systems Status and Plans ~25% Gian. Luca Sabbi

LARP Magnet Development Chart Completed • Length scale-up • High field • Accelerator features

LARP Magnet Development Chart Completed • Length scale-up • High field • Accelerator features CM 14, 4/26/2010 Magnet Systems Status and Plans Achieved 200 T/m 1 st test 4/2010 Gian. Luca Sabbi

Pre-Chamonix Planning Discussions 2010 -2012: complete technology demonstration (original goal) LQ to address all

Pre-Chamonix Planning Discussions 2010 -2012: complete technology demonstration (original goal) LQ to address all length-related issues (& fully reproduce TQ results): • 2010 -2011: • 2011(2012): 2 -3 additional tests using 54/61 coil series Fabricate 4 -6 additional coils using 108/127 ~2 tests with 108/127 coil series HQ to address field/energy limits and accelerator quality • 2010 -2011: 3 -4 tests with 1 m models Progressively push performance • 2011 -2012: Extend to 1. 5 or 2 m length Use Phase 1 specifications as reference 2012 -2014: fabricate and test IR Quad prototype 2015 -2020: IR quad production for Phase 2 upgrade CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

Recent Technical Progress Dec. 2009 Feb. 2010 Mar. 2010 Apr. 2010 CM 14, 4/26/2010

Recent Technical Progress Dec. 2009 Feb. 2010 Mar. 2010 Apr. 2010 CM 14, 4/26/2010 First Long Quadrupole (LQS 01 a) test • Achieved target gradient of 200 T/m TQS 03 c high stress test (CERN) • 88% SSL w/200 MPa average coil stress TQS 03 e cycling test (CERN) • No degradation after 1000 cycles First High-Field Quadrupole (HQS 01 a) completed • 120 mm, designed for 15 T & field quality LQS 01 b assembly completed • Improved stress distribution and higher stress HQS 01 a test is underway Magnet Systems Status and Plans Gian. Luca Sabbi

LQS 01 & TQS Quench Performance Comparison of first training sequences at each temperature

LQS 01 & TQS Quench Performance Comparison of first training sequences at each temperature with all new coils 200 T/m Note: LQS 01 & TQS 02 use same strand design (RRP 54/61) 4. 5 K CM 14, 4/26/2010 ~3 K Magnet Systems Status and Plans 1. 9 K Gian. Luca Sabbi

LQS 01 Test: Strain Gauge Measurements SHELL COOL-DOWN Design target, 4. 5 K Design

LQS 01 Test: Strain Gauge Measurements SHELL COOL-DOWN Design target, 4. 5 K Design target, 293 K COIL (Ti POLE) COOL-DOWN AXIAL RODS COOL-DOWN Unloading Design target, 4. 5 K Design target, 293 K CM 14, 4/26/2010 COIL (Ti POLE) EXCITATION Magnet Systems Status and Plans Gian. Luca Sabbi

Analysis of Mechanical Results • Observed behavior attributed to coil-pad surface mismatch • Can

Analysis of Mechanical Results • Observed behavior attributed to coil-pad surface mismatch • Can be compensated by removing G 10 shim at interface • Eventually, coil oversize needs to be corrected by tooling/process FEA analysis CM 14, 4/26/2010 Pressure-sensitive film test Magnet Systems Status and Plans Gian. Luca Sabbi

LQ Plan 2010 -11 CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca

LQ Plan 2010 -11 CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

TQS 03 c High Stress Test Coil layer 1 stress evolution - sq Calculated

TQS 03 c High Stress Test Coil layer 1 stress evolution - sq Calculated peak stresses in TQS 03 c 260 MPa @ 4. 5 K Systematic investigation in TQS 03: • TQS 03 a: 120 MPa at pole, 93% SSL • TQS 03 b: 160 MPa at pole, 91% SSL • TQS 03 c: 200 MPa at pole, 88% SSL Peak stresses are considerably higher Considerably widens design window CM 14, 4/26/2010 Magnet Systems Status and Plans 255 MPa @ SSL Gian. Luca Sabbi

TQS 03 e Cycling Test • Reduced coil stress to TQS 03 b levels

TQS 03 e Cycling Test • Reduced coil stress to TQS 03 b levels (160 MPa average) Ø Pre-loading operation and test performed at CERN • Did not recover TQS 03 b quench current (permanent degradation) • Performed 1000 cycles with control quenches every ~150 cycles • No change in mechanical parameters or quench levels CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

HQ Progress 2008 2009 2010 CM 14, 4/26/2010 June July Sept. Dec. Mar. Apr.

HQ Progress 2008 2009 2010 CM 14, 4/26/2010 June July Sept. Dec. Mar. Apr. Sept. Nov. Dec. Jan. Feb Mar Apr. Presented conceptual designs for 114 and 134 mm bore Selection of 120 mm quadrupole aperture for Phase 1 Cable and coil cross-section geometry finalized All coil fabrication tooling in procurement All coil and structure components in procurement Cables for ~10 coils fabricated (54/61 and 108/127) Coil 1 completed and coil 2 wound CM 13 Coil 2 completed, coil 3 -4 reacted, coil 5 wound Structure pre-assembly completed Coil 1 -4 completed Assembly completed Coil #5 completed, #6 potted, #7 reacted, #8 wound HQ 01 a test underway Magnet Systems Status and Plans Gian. Luca Sabbi

Coil and Structure Fabrication Layer 1 Winding Layer 2 Winding Structure assembly Instrumentation trace

Coil and Structure Fabrication Layer 1 Winding Layer 2 Winding Structure assembly Instrumentation trace Coil 1 Quench heater Alignment slot CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

HQ 01 a Test Status and Next Steps • Cool-down completed (4/19 -22): Next

HQ 01 a Test Status and Next Steps • Cool-down completed (4/19 -22): Next steps: • 4/26 -30: Heater tests, magnetic measurements • 5/3 -7: Quench training CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

HQ Next Steps • One-meter model optimization: Ø Pre-load, alignment, quench protection and thermal

HQ Next Steps • One-meter model optimization: Ø Pre-load, alignment, quench protection and thermal studies Ø Cored cables to control dynamic effects Ø Structure optimization for production and accelerator integration • Two-meter extension: field quality & comparison with Nb. Ti models Radial bladders/keys Cooling channels Laminated collar Pressure vessel/end terminations CM 14, 4/26/2010 Support/alignment fiducials Magnet Systems Status and Plans Gian. Luca Sabbi

HQ Plan 2010 -11 CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca

HQ Plan 2010 -11 CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

Materials R&D Three strand designs used in LARP: • MJR 54/61: TQS 01, TQC

Materials R&D Three strand designs used in LARP: • MJR 54/61: TQS 01, TQC 01, SQ • RRP 54/61: LR, TQ 02, LQS 01(2), HQ 01 • RRP 108/127: TQS 03, HQ 01 a, (LQS 03) RRP 54/61: J Production wire, highest Jc, long piece length, best characterized Large sub-elements, flux jumps esp. in larger diameter wires RRP 108/127: J Deff reduced by 30%, very good results in TQS 03 10 -20% lower Jc, not fully optimized for production New options from the HEP Conductor Development Program: • Ti-doped RRP: HQ cable/coil will be fabricated in 2010 • RRP 217: promising but still requiring R&D CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

Cable R&D Stable and consistent cable production: TQ (30 UL, 65 m each); LQ

Cable R&D Stable and consistent cable production: TQ (30 UL, 65 m each); LQ (15 UL. 200 m each); LR (3 UL, 200 m each); HQ (10 UL, 100 m each) Production so far has followed a 2 -step process: Ø First pass cable followed by anneal and re-roll Next R&D steps: Ø Ti-doped RRP wire (to qualify for purchase by LARP) Ø One-pass cable w/pre-annealed wire (lower cost, SS core) Ø Addition of a SS or glass core (control of dynamic effects) • R&D cables will be tested in HQ 1 -meter coils • Best results to be incorporated in HQ 2 -meter models CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

Length considerations for the IR upgrade • HQ short sample gradient is 200 T/m

Length considerations for the IR upgrade • HQ short sample gradient is 200 T/m @ 4. 5 K & 220 T/m @ 1. 9 K • Assume operation at 170 T/m and same basic layout as baseline LHC magnet length is ~7. 4 m (Q 1 & Q 3), 6. 4 m (Q 2 a & Q 2 b) • Half length elements: ~4. 1 m (Q 1/Q 3), ~3. 5 m (Q 2 a/b) w/10% factor Technical comparison: - Full length elements are clearly preferred for optimal IR performance - Full length elements should be less costly for production Ø However, they require new infrastructure - Full length elements need to be demonstrated experimentally Ø This can impact the schedule and decision process - Half-length elements could be considered as a fall-back solution Ø Loss of efficiency is 5 -15% depending on implementation CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

Medium term Nb 3 Sn development (2012 -14) Goal: demonstrate full-length magnet performance to

Medium term Nb 3 Sn development (2012 -14) Goal: demonstrate full-length magnet performance to minimize the technical and schedule risk to the project • The existing (FNAL) infrastructure allows fabrication of coils up to 6 m length. • As a first step, we could aim at testing of individual 6 m long coils in a suitable support structure by 2014 • The 6 m long coils could be based on LR, LQ or HQ design Ø The 120 mm (HQ) design is strongly preferred since it could directly lead to assembly of a 6 m long IR Quad prototype Ø However, is more expensive to fabricate and test then the other two alternatives • Results of 2 m model Quadrupoles and 6 m coil scale-up will provide required information for detailed IR design and project planning/initiation CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

Production schedule Define production line: complete set of winding, curing, reaction, potting infrastructure, tooling,

Production schedule Define production line: complete set of winding, curing, reaction, potting infrastructure, tooling, crew Assuming that a production line delivers one coil every four weeks: 64 coils ~7 m long: ~5 years with 1 production line ~2. 5 years with 2 production lines One year from coil production to magnet production completion Questions: • Set-up time (infrastructure and tooling) Ø LARP can contribute to an efficient start • Ramp up time, how long and what productivity • Process optimization for production • Conductor procurement schedule CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

From R&D to Construction The LARP R&D program components will inform the decision process

From R&D to Construction The LARP R&D program components will inform the decision process and develop the IR Quad design, tooling and fabrication process: • LQ, HQ-1 m & HQ-2 m provide a basis for the 2013 technology choice • 6 -m mirror program provides a basis for tooling design & coil fabrication • 6 -m Quadrupole program provides a basis for IR Quad structure/assembly CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi

Summary • Significant technical progress during the last 6 months: LQ 200 T/m milestone

Summary • Significant technical progress during the last 6 months: LQ 200 T/m milestone and further optimization, robust performance in TQ, and completion of the first HQ • The near term magnet R&D plan (2010 -2012) is well aligned with a technology decision in 2013 Ø Systematic testing of LARP Nb 3 Sn models and CERN Nb. Ti models with same specs will provide direct technology comparison and qualification • The medium term magnet R&D plan (2012 -2014) is being formulated with the goal of minimizing the technical and schedule risk for construction Ø Extension of the HQ design to 6 m length appears to be the most effective strategy CM 14, 4/26/2010 Magnet Systems Status and Plans Gian. Luca Sabbi