Christian Lffler and Emelie Nilsson 19102016 11 T

Christian Löffler and Emelie Nilsson 19/10/2016 11 T dipole coil features and dimensions 1

Outline • Main parameters of the coil • Nominal vs measurements • Coil cross section – nominal vs inspected coil segment • Cable insulation • Nominal vs measurements 2

Tolerances on the coil Angle Loading Plate ± 0. 2°, nominal 18. 387° • Outer Radius ± 0. 15 mm, nominal 60. 8 mm • Azimuthal(AZ) Branch Length ± 0. 15 mm, nominal 0. 15 mm • • • AZ-Length is a function of the arc length and the outer diameter 0. 1 mm deviation is corresponding to a change of 15 MPa in Coil Block 4, in AZ-Stress. This is confirmed by FEA, Mechanical Measurements and FUJI-paper analysis. Internal Reference: FEA version: 1607 -1 in 1 -cable. V 3_3; FUJI-Paper measurement: EDMS 1726385 3

Results from previous coils • m 0 m For analysis coil separated in Ends, Center and Left and Right-Branch d En m 0 -> 4 values per coil • • • LP-Angle Outer Radius Azimuthal Excess 0 m Features analyzed • 50 0 1 50 0 0 d n E 0 m 0 r 5 0 -1 0 m e t en C 10 4

Results from previous coils Loading Plate - Angle / min-max 0, 60 Tolerances ± 0. 2° 0, 40 Center End 0, 30 80 EDMS 1726385 75 0, 20 pressure / MPa LP-Angle Deviation / degree 0, 50 0, 10 0, 00 -0, 10 70 65 60 55 50 45 40 -0, 20 35 0 -0, 30 106 107 Ends LP-angle left 108 109 110 Center LP-angle left Left-Branch 111 112 113 Coil # Ends LP-angle right 114 115 CR 1 Center LP-angle right Right-Branch 5 10 15 20 25 radial axis / mm (0=inner diameter) c 114 l AV 350 mm c 114 r AV 350 mm c 115 l AV 350 mm c 115 r AV 350 mm Radial pressure distribution during pre-collaring of SP 105, average over 10 mm longitudinal. Measured with FUJI-Paper. 30 5

Results from previous coils Outer Radius / min-max Outer Radius Deviation / mm 0, 20 0, 10 0, 00 -0, 10 -0, 20 Tolerances ± 0. 15 mm -0, 30 -0, 40 -0, 50 106 107 108 109 Ends outer radius left Ends outer radius right 110 111 112 113 114 115 CR 1 Coil # Center outer radius left Center outer radius right Best-Fit of a non constrained circle on the measured point on the outer radius. 6

Results from previous coils Azimuthal Excess / min-max 0, 50 Branch length Azimuthal Excess / mm 0, 40 0, 30 0, 20 0. 15 mm Goal 0, 10 0, 00 only in the very end of the straight section -0, 10 Azimuthal Excess -0, 20 106 107 108 109 Ends azimuthal excess left Ends azimuthal excess right 110 111 112 113 114 115 CR 1 Coil # Center azimuthal excess left Center azimuthal excess right Tolerances ± 0. 15 mm 7

Comparison with coil segment coil #107 • • • Nominal conductor position compared to the inspected cross section of a segment from coil #107 (photograph from MME) Deviation of radial position of inner layer blocks Reduced radial space between conductors near mid plane Due to over compression at some point (when closing the reaction/impregnation moulds)? 8

Image analysis on coil segment 1. Detect cable contours For MQXF: E. Rochepault et al. IEEE 2016 2. Fit them to trapezoids 9

Summary of analysis conductor growth • Cables are curved on the middle Fit 1/8 of the length near each end SEGMENT FROM COIL 107 Nominal (mm) Photograph + Tomography + image analysis (block 1 & 5) Scheuerlein (block 1 & 5) Width 14. 85 (1%) 14. 715 (0. 1%) 14. 787 (0. 6%) 14. 76 (0. 4%) Mid thickness 1. 306 (4. 5%) 1. 272 (1. 8%) 1. 322 (5. 8%) 1. 296 (3. 7%) Uncertainties in measurement method and pixel sixe. 10

• • Cables seem to be systematically ‘bent’, in the upward direction MICA is C-shaped with an opening on the top side (coincidence? ) 11

Cable insulation Insulation thickness (design values) MICA layer 0. 080 mm Fibre braiding 0. 075 mm Total insulation thickness 0. 155 mm (0. 100 mm under 30 MPa compression) Nb 3 Sn Cable, Mica insulation, Glass Sleeved 12

10 stack measurements insulation thickness • • • Measurements show that the total insulation thickness in the range 110 -115 μm. Tooling designed considering compression of the cable at 30 MPa with wall thickness of 100 μm. Original braiding: yarn count 14/2 cm (Coil 105 -107, 110). Updated braiding: yarn count 12/2 cm. Results from 10 -stack measurements Original braiding Updated braiding coil Ins thickness @ 30 Mpa (μm) 105 106 107 108 109 110 111 112 113 114 115 116 117 114 114 107 113 106 114 112 113 112 140 Thickness S 2 -glass +MICA (um) • 130 coil 112 120 coil 113 coil 116 coil 117 110 100 0 5 10 15 20 25 30 35 Compression (MPa) 13

Measurement of MICA thickness Measure 1: 10 layers of MICA piled up Thickness per layer of MICA: Measure 2: MICA between bare cables in 10 -stack config. 14

Modify braiding parameters Attempt to reach design value 0. 100 mm Insulation thickness S 2 glass 11 TEX 636 [µm] S 2 -glass Braiding parameters Yarn count/2 cm #1 11 T reference #2 #3 #4 #5 12 12 12 18 17 -18 No. of brins 9 6 5 5 4 4 # 5 b (with MICA) 15

Results 10 -stack measurements Insulation thickness S 2 glass 11 TEX 636 [µm] Pressure [MPa] #1 11 T ref. #2 #3 #4 #5 5 93 66 57 70 58 100 10 89 63 54 66 55 93 20 85 59 50 63 52 88 30 82 57 48 61 50 84 20 82 57 49 61 50 85 10 83 58 50 62 51 86 5 85 60 51 64 52 87 # 5 b (with • • MICA adds ~35 um (Difference #5 to #5 b) Samples to be produced and measured with MICA) Prediction of 1. # 4 (18 yarn counts/2 cm, 5 brins) with MICA : ~96 um 2. # 4 (18 yarn counts/2 cm, 6 brins) : ~105 µm • Plan to reach nominal with new braiding parameters (2 nd generation short model). • Also for 1 st generation long coil? 16

Heat Treatment MICA layers to avoid gluing, removed after HT • • • 1 layer 0. 125 mm MP 1 layer of MICA 0. 125 mm on OL 1 layer of MICA 0. 125 mm on IL – tooling designed for 2 layers Coil already oversized before heat treatment? • • • Rmandrin = 29. 75 mm Rcoil, inner = 30. 0 mm Rcoil, outer = 60. 6 mm LHCMBHST 0009 17 17

Conclusion • Short models produced: • • Segment of coil #107 analysed. • • 3/11 coils with outer radius within tolerances. 6/11 coils with loading plate angle within tolerances. 7/11 coils with azimuthal excess within tolerances. Coils are all azimuthally oversized! Difficult to quantify cable dimensions. Visible radial deviation from nominal cable positions. To exclude effect from ‘cutting’, useful to look inside coil segment: tomographic measurements will be presented in talk later today. Strategy to reach design values of cable insulation (100 μm @ 30 Mpa) • • • New braiding parameters are being explored. To be implemented for 2 nd generation 11 T coil design. Interesting also for 1 st generation long model? 18

Extra slides 19

Main parameters of the coil Coil: 56 turns, 2 layers, 6 blocks design, no internal splice Coil ID / OD 59. 8 / 121. 6 mm Coil overall length 5559 mm Straight section length 5108 mm Turns Inner Layer (IL) / Outer Layer (OL) Impregnation System 22 (IL) / 34 (OL) Epoxy DGEBA (CTD 101 -K) Cable : RRP 0. 7 mm dia. , 40 strands, cored, glass-mica insulated Cable Length (IL / OL / on spool) Cable bare width before / after reaction Cable bare mid-thickness before / after reaction Keystone angle before / after reaction Number of strands per cable (x strand diameter) Cable insulation wall thickness (design value) Insulation Material 235 (IL) / 364 (OL) / 680 m 14. 7 / 14. 85 (+1%) mm 1. 25 / 1. 306 (+4. 5%) mm 0. 79 / 0. 806 deg. 40 (x 0. 7 d [mm]) - 0. 1 mm Phlogopite + Glass 20 20