EucardWP 7 HFM 10 th Collaboration Meeting at

Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano Eu. Card-WP 7 -HFM 10 th Collaboration Meeting Status on SMC & RMC Models J. C Perez on behalf of SMC/RMC collaboration team

• • SMC configuration Status on coil fabrication for SMC 3_b and SMC_11 T Reaction furnaces status From SMC to Fresca 2 through RMC structure fabrication Sub-scale models activities Next SMC & RMC Coils Summary 2 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano Outline

Longitudinal compressing system for the rods Vertical key Iron yoke Lateral pad Vertical pad Longitudinal rods Racetrack coil Coil pack and Iron yoke mounted in the instrumented Al 2219 T 851 shell 3 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano SMC configuration

SMC Coils J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano • 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 • Nb 3 Sn/Nb. Ti splice integrated in the end-saddle connection side • Instrumented with Vtaps and strain gauges using dedicated printed circuits (“Traces”) J. C. Perez / TE-MSC-MDT 4

• Status • 2 coils for SMC 3_b using PIT 14 x Ø 1. 25 mm strand with Ti-islands and spacers wound in September 2011 • Electrical insulation of the central island spacers with Al 2 O 3 plasma spray coating • Cable insulated with S 2 -Glass sleeve • Plan • Heat treatment on Argon atmosphere furnace @ CERN (October 2012, delayed till now due to furnace setting up problems see later) • Coils to be potted using Epoxy NY 750 & Jeffamine D-400 • Magnet assembly scheduled Q 4 -2012 • Cold powering tests scheduled end Q 4 -2012 5 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano SMC#3_b coils fabrication status and program

• • Single pancake coil configuration Cable dimensions: 14. 7 * 1. 27 mm 2 * 35 turns Iss: 15590 A Bpeak: 13. 8 T (@ 1. 9 K) J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano SMC Coils for 11 T cable Cable insulation: • 150 µm S 2 -Glass 33 Tex braided directly on the cable (Coil #1. See film) • 90 µm Mica(*) with 70 µm S 2 -Glass 11 Tex braiding (Coil #2) S 2 -Glass (*)Cablosam® AP - PG 90 366. 20 -81 by Von Roll 6 Mica

• The first SMC coil using 11 T type cable has been wound in July 2012 • The coil will be heat treated after the reaction of SMC#3_b coils (end of November 2012) • Cold powering tests planed for Q 1_2013 7 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano First SMC Coil with 11 T type cable

• The retro-fitting of the “Borel” reaction furnace has been launched in summer 2011 • After several thermal cycles necessary to calibrate the furnace and reduce the over-shoot, the temperature control is fully operational • Several runs with samples of Nb 3 Sn have been made and Jc measurements have been performed to validate the cycles • The sarcophagi and all pipes for injection and exhaust of the Ar gas have been cleaned • A new O 2 trap system has been installed • A security valve calibrated at 300 mbar has been added onto the return gas circuit to avoid overpressure in the sarcophagi during the heat treatment process • A new heat treatment cycle with 6 wire samples, copper and stainless steel cylinders, has started last week to confirm that the treated pieces are not polluted during the treatment 8 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano Reaction Furnace Status

J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano Pictures of the Reaction Furnace 9

• A new reaction furnace to treat SMC like coils has been ordered and will be installed @ CERN • Main characteristics: • • • Hood furnace 13000 C Thermal stability ± 30 C Retort (L x W x H) 730 x 300 x 400 mm Inert gas circulation O 2 analyser 10 thermocouples for temperature monitoring and control • Delivery and commissioning @ CERN expected for end of October 2012 • This will make the SMC line independent from other magnet programs 10 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano SMC coils type Reaction Furnace

J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano Pictures of SMC coils type Reaction Furnace 11

SMC FRESCA 2 RMC J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano From SMC to FRESCA 2 through RMC • RMC goals: test FRESCA 2 type cable and FRESCA 2 -type coils in realistic conditions • Constraints 1. Layer jump similar to FRESCA 2 2. Power supply limit ~20 k. A 3. Magnet OD: 570 mm 12 Courtesy of M. Timmins

• Same design as SMC – 2 end spacers – 33 turns (like FRESCA 2) • FRESCA 2 -type layer jump • As a result – Straight section: 300 mm • 150 mm in SMC – Coil length: 820 mm • 500 mm in SMC – 96 m of cable per coil • 4. 0 km of strand RMC coil J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano RMC Coil design for FRESCA 2 type cable FRESCA 2 coil Courtesy of P. Ferracin 13

• RMC configuration – 2 RMC coils • Iss (1. 9 K) = 18. 3 k. A – Below power supply limit • Bpeak = 16. 0 T – Significantly higher forces • From 2. 2 MN/m in SMC to 5. 4 MN/m – New structure required • Thicker shell, new yoke design, larger bladders, larger axial rods 14 RMC J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano RMC Magnet Design

J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano RMC 1 double pancake vs. 2 double pancakes • Still possible to test individual coils up to 20 k. A • Corresponding to about 93% of Iss @ 4. 2 K 15

Aluminium Shell Longitudinal compressing system Yoke Nb 3 Sn/Nb. Ti Splice Vertical Pad Horizontal Pad Connexion box Racetrack Coil 16 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano RMC Magnet Design

• RMC project was accepted in December 2011 • All fabrication drawings completed by end of March 2012 • A call for tender for mechanical structure launched in April 2012 • The order of the structure components has been placed in a Spanish company and the delivery is expected by end of November 2012 • Coil parts and reaction mold have been ordered and delivered in June 2012 • Ti central islands and stainless steel spacers have been plasma spray coated using Al 2 O 3 • The order for the close impregnation mold has been placed. Delivery is expected for October 2012 • The first length of copper cable, insulated using 66 Tex S 2 -Glass fiber braiding technique, will be delivered end of September 2012 • First winding tests, using dummy Cu cable, are scheduled in October 2012 • First mechanical assembly after structure instrumentation are planed for Q 4 -2012 17 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano RMC Design Status

Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano RMC Parts

Insulating plate Nb. Ti Lead Rail End Shoe Coil Nb 3 Sn/ Nb. Ti Splice Filler piece Copper stabilizer Nb 3 Sn Cable 19 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano Splice Area Design on RMC from Fresca 2 Magnet

RMC Protection and Instrumentation Traces • • Two independent protection heaters circuits using 50 µm Kapton® and 25 µm stainless steel sheets Two strain gauges stations to record the transversal forces on the coil Six voltage taps The trace connection from the coil to the cryostat, using instrumentation wires, will be hidden in a pocket machined on the end-spacer connection side 20 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano Each double pancake coil will be equipped with 2 traces including:

E glass (with Boron) Not found on the E-CR glass (Boron free) market De-sizing Re-sizing Braiding J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano Fibber Glass selection program for direct braiding S-2 Sizing 636 (Starch) 11/33/66 TEX S-2 Sizing 493 33/66 TEX Compatible with Epoxy Polyester Suggested for high temperature S-2 Sizing 933 66 TEX Compatible with Cyanate ester Polyimide Epoxy Designed for high temperature Braiding 21 Reaction

in m te ed lu e va en t Ultimate Strength [MPa} 3500 e am fil sin gl gl e sin re tu er a lit ar an gu E tu re er a lit 4000 st ra nd fo r. E E be C 9 fo 66 re AS re ac E TM af tio te ex n rr S 2 tra ea lit po ct er la io at te n ur d S 2 e gu s in ar lit gl an er e at te fil ur ed am e va s en i ng lu t e l e fo S 2 st r ra 93 vi S 2 nd rg 3 63 i be n 6 S SC fo 2 be 93 re 9 S 2 fo 66 3 re re 49 be ac r 3 e f tio or ac be e n tio fo re ex r n e ac tra r tio ea ct n ct ed from ion m bo w bb ea in ve S 2 d tis 63 su 6 e af te S 2 r 49 de 3 -si af zi te S 2 r d ng c 93 yc e 3 le siz Ex af pe in te gc rd ct ed yc ele s fro izi n m g lit cy er cle at ur e af te S 2 rr 63 ea 6 ct af io te S 2 n rr 49 e ac 3 af tio te S 2 n rr 93 ea 3 ct af io te n rr ea ct io n M AS T 5000 4500 3500 2500 AGY S 2 493 3000 Color after de 3100 sizing 2400 1000 500 636 493 Glass fiber 4600 after 100 S-2 hours at S-2650 C S-2 933 Original Color White AGY S 2 636 White Slightly Grey White 876 AGY S 2 933 2000 1500 1131 732 54 22 of P. Fessia Courtesy E glass Slightly Grey 1821 Color after heat Grey treatment 1897 1372 759 979 938 838 500 352 359 348 0 J. C. Perez TE/MSC-MDT E Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano S-2 Glass: tensile test after de-sizing and reaction

• The S-2/933 has been selected as the best solution for the direct braiding. We aim avoiding de-sizing • A full palette of material has been procured and delivered at CERN on the 11/09. It has required special production for us that has taken the whole summer • Next steps – Repetition of test on “virgin” yarn – Bonding test on fibers before and after reaction – Bonding and mechanical test on fibers with ceramic binders before curing, after 1 and 2 curing, after reaction and in function of ceramic binder quantities • We have also identified supplier ready to braid for us tapes from our S-2 933 yarns (collaboration with RAL) Courtesy of Polymer Laboratory 23 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano Conclusions and follow-up of the insulation program

• • Characterization on strand performance in realistic SMC conditions (SMC 4 & SMC 5) Characterization on strand cable performance DS 11 T in realistic conditions for wide cables ( RMC) Layer jump area (RMC) Fresca 2 Splicing area (RMC) Braided insulation (SMC & RMC) Traces connection (RMC) Impregnation method for Fresca 2 type coils (RMC - Close mold) Qualification of new vacuum impregnation tank. Qualification of new oven (SMC & RMC) 24 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano On going activities on sub-scale models

SMC Assembly SMC#3_b Cable Type Cable Insulation PIT 14 * Ø 1. 25 mm Scheduled S 2 -Glass sleeve FNAL type 2 Coils waiting for reaction SMC#11 T_a (1 coil) OST RRP 108/127 40 * Ø 0. 7 mm 33 Tex S 2 -Glass braided Coil waiting for reaction SMC#11 T_b (1 coil) OST RRP 108/127 40 * Ø 0. 7 mm 11 Tex S 2 -Glass braided & Mica 90 µm Q 4 -2012 SMC#4 (2 coils) PIT 18 * Ø 1. 00 mm S 2 -Glass sleeve 100 µm or S 2 -Glass braided Q 4 -2012 SMC#5 (2 coils) RRP 18 * Ø 1. 00 mm TBD Q 2 -2013 25 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano Next SMC assembled coils

Next RMC Coils Production Cable Type Cable Insulation Scheduled RMC#0 coil 1 Cu 40 * Ø 1. 0 mm S 2 -Glass 66 Tex braided Q 4 -2012 RMC#1 coil 1 PIT 40 * Ø 1. 0 mm S 2 -Glass 66 Tex braided Q 1 -2013 RMC#1 coil 2 PIT 40 * Ø 1. 0 mm S 2 -Glass 66 Tex braided Q 2 -2013 Conductor availability? RMC#2 coil 1 RRP 40 * Ø 1. 0 mm S 2 -Glass braided Or according to FRESCA 2 choice Q 3 -2013 RMC#2 coil 2 RRP 40 * Ø 1. 0 mm S 2 -Glass braided Or according to FRESCA 2 choice Q 3 -2013 Conductor availability? 26 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano RMC Assembly

• The Borel heat treatment furnace should be operational by end of September • SMC#3_b and SMC#11 T_a coils will be heat treated in October • SMC#11 T_b (mica insulation) will be wound after reaction of SMC#11 T_a • SMC#3_b Cold powering tests scheduled for end 2012 • SMC#4 and SMC#5 will be used to compare PIT and RRP cables • Coil parts for SMC#4 and SMC#5 have been ordered and will be plasma spray coated with Al 2 O 3 • SMC#4 coils winding is scheduled Q 4 -2012 • The SMC coils type heat treatment furnace will be installed and commissioned in 927 in October 2012 27 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano Summary (1/2)

• RMC will be used to characterize strand cable performance in realistic conditions for wide cables • RMC coils will be used to validate technical choices to be applied on Fresca 2 coils fabrication • RMC structure delivery scheduled for November 2012 • First RMC coil using a copper cable will be wound Q 4_2012 • RMC trace will installed in the copper coil will be used to validate Fresca 2 trace design • RMC impregnation mold will validate Fresca 2 coil impregnation procedure • First RMC cold powering test with a single coil configuration is scheduled early 2013 28 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano Summary (2/2)

H. Bajas, M. Bajko, B. Bordini, S. Canfer, S. Clement, G. de Rijk, G. Ellwood, P. Ferracin, J. Feuvrier, E. Fornasiere, R. Gauthier, C. Kokkinos, M. Guinchard, J. Humbert, P. Manil, A. Milanese, M. Timmins, L. Oberli, J. C. Perez, F. Rondeaux TE/MSC-MDT Section 29 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 10 th Collaboration Meeting at LASA Milano SMC/RMC collaboration team