EucardWP 7 HFM 9 th Collaboration Meeting at

Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology Eu. Card-WP 7 -HFM 9 th Collaboration Meeting Status on SMC & RMC Models J. C Perez on behalf of SMC collaboration team

• • What’s SMC? Tests results on SMC 3_a Coil fabrication for SMC 3_b SMC_11 T From SMC to Fresca 2 through RMC Sub-scale models activities Next SMC & RMC Coils April 24 th 2012 2 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology Outline

SMC is a tool to learn and test : Ø Technologies needed for a Nb 3 Sn based high field magnet fabrication: • • • Cable insulation Coil reaction Coil impregnation Trace fabrication Bladder fabrication Ø Techniques of coil fabrication and magnet assembly • • • Winding Coil instrumentation and Protection Structure instrumentation Magnet assembly with bladders and keys Nb 3 Sn/Nb-Ti cable connection SMC is a tool to qualify: Ø Nb 3 Sn cables in a real magnet configuration April 24 th 2012 SMC is the “STEP 0” to build a Nb 3 Sn accelerator magnet for Eu. CARD-WP 7 and at CERN 3 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology WHAT’s SMC?

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 April 24 th 2012 4 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology SMC configuration

12/12/2011 Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology SMC Coils • 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 stain gauges using dedicated printed circuits (“Traces”) J. C. Perez / TE-MSCJ. C. Perez MDT / TE-MSC-MDT 5

Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology SMC#3_a coils fabrication • 2 coils for SMC 3 with PIT 14 x Ø 1. 25 mm strand with Ti-islands and spacers wound in November 2010 • Cable insulated with S 2 -Glass sleeve (FNAL type) • Electrical insulation of the central island on the layer jump area with ceramic 989 F • Heat treatment in a vacuum furnace @ CERN • Coils potted using Epoxy NY 750 & Jeffamine D-400 • Electrical problems on spacers insulation, low longitudinal pre-load • Magnet assembled in May 2011 • 1 st assembly: 2 runs of cold powering tests performed in the new vertical test station (SM 18) in June and September 2011 • 2 nd : reloading to increase pre-stress on coils and magnet retested in December 2011 J. C. Perez / TE-MSC-MDT 6

SMC#3 Training 16000 Run 1 Quench current, Iq [A] 15000 95 % Iss @4. 2 K Run 2 after thermal cycle 91 % Iss @1. 9 K 13. 92 T 12. 82 T 14000 Run 3 with higher pre-stress 13000 @ 1. 9 K 12000 @ 4. 2 K 11000 85 % Iss @4. 2 K 74 % Iss @4. 2 K 10000 0 5 Iss@ 1. 9 K( opera 3 D) Iss@ 4. 3 K( opera 3 D) 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Quench history Courtesy of H. Bajas April 24 th 2012 7 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology SMC#3_a cold tests results

• 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 (FNAL type) • Plan • Heat treatment on Argon atmosphere furnace @ CERN or CEA-Saclay scheduled on May 2012 (CERN furnaces failure) • Coils to be potted using Epoxy NY 750 & Jeffamine D-400 • Magnet assembly scheduled end Q 2 -2012 • Cold powering tests scheduled during summer 2012 April 24 th 2012 8 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology SMC#3_b coils fabrication status and program

• • Single pancake coil configuration Cable dimensions: 14. 7 * 1. 27 mm 2 * 37 turns Iss: 15950 A Bpeak: 14. 08 T Cable insulation: • 150 µm S 2 -Glass braiding directly on the cable • 90 µm Mica(*) with 70 µm S-Glass braiding (*)Cablosam® AP - PG 90 366. 20 -81 by Von Roll April 24 th 2012 9 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology SMC Coil for 11 T cable

SMC FRESCA 2 RMC J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology From SMC to FRESCA 2 through RMC • RMC goals: test FRESCA 2 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 April 24 th 2012 10 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 9 th Collaboration Meeting at Warsaw University of Technology RMC Coil design FRESCA 2 coil Courtesy of P. Ferracin April 24 th 2012 11

• 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 April 24 th 2012 12 RMC J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology RMC Magnet Design

J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology 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 April 24 th 2012 13

• • • Fabrication drawings for coil components, reaction and impregnation tooling approved for execution First winding scheduled for September 2012 Mechanical structure design finished. Fabrication drawings are expected end of April. First mechanical assembly using an instrumented aluminum dummy coil scheduled for September First cold test expected Q 4 -2012/Q 1 -2013 April 24 th 2012 14 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology RMC Design Status

• • Characterization on strand cable performance Layer jump area Splicing area Insulation method Traces connection Impregnation method Qualification of new vacuum impregnation tank Qualification of new oven April 24 th 2012 15 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology Sub-scale models activities

Insulating plate Nb. Ti Lead Rail End Shoe Nb 3 Sn/ Nb. Ti Splice Filler piece Copper stabilizer Nb 3 Sn Cable April 24 th 2012 16 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology Splice Area Design on Fresca 2 Magnet

R 1 R 2 R 3 R 4 Central Post Spacers set R (GΩ) @ 1000 V ( R 1 to R 6) R (GΩ) @ 2500 V (R 1 to R 6) Central post 1 1 73 52 Central post 1 2 73 52 Central post 2 1 73 52 Central post 2 2 73 52 Central Post 1 after Thermal cycle @ 77 K 1 73 52 Central Post 1 after Thermal cycle @ 650 0 C 1 73 52 R 5 R 6 Spacers are coated with Plasma Spray Al 203 & Ni/Cr 80/20 April 24 th 2012 17 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology Coated spacers insulation tests

• Fibers – Desizing: test heat process vs. chemical process – Sizing: palmitic acid (machine under construction) vs. inorganic sylane (if they exist …) – E-glass vs S 2 -glass: how much do we gain ? ? ? • Tapes – Procure and perform mechanical tests on possible tapes – Combine mechanical tests with electrical tests on impregnated fibers – Make available a proper tooling or supplier for the tape wrapping • Braiding – Machine ready to braid from 8 to 22 mm wide cable – Procurement of S 2 yarn under study – Big question to solve the sizing • Ovens to test fibers – Very small oven available (diameter 40 mm length 40 mm) – New oven available (160 mm diameter and useful length for this kind of test 350 mm) April 24 th 2012 18 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology CERN/RAL cable insulation development program

• Traces design and fabrication @ CERN using 50 µm Kapton® and 25 µm stainless steel sheets. • The connections will be hidden in a pocket machined on the end-shoe connection side (mold released) • No wires will come out from the mold during impregnation process • After coil impregnation, wires will be soldered to the traces and routed via a groove machined on the end-shoe (local impregnation) April 24 th 2012 19 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology Quench Heaters & Traces

• • 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) April 24 th 2012 20 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology 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 OST RRP 108/127 40 * Ø 0. 7 mm 33 Tex S 2 -Glass braided Q 2 -2012 SMC#11 T_b OST RRP 108/127 40 * Ø 0. 7 mm 11 Tex S 2 -Glass braided & Mica 90 µm Q 2 -2012 SMC#4 PIT 18 * Ø 1. 00 mm S 2 -Glass sleeve 100 µm or S 2 -Glass braided Q 3 -2012 SMC#5 RRP 18 * Ø 1. 00 mm TBD Q 4 -2012 April 24 th 2012 21 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology Next SMC assembled coils

RMC Assembly Cable Type Cable Insulation Scheduled RMC#0 coil 1 Cu 40 * Ø 1. 0 mm S 2 -Glass braided Or according to FRESCA 2 choice Q 3 -2012 RMC#1 coil 1 PIT 40 * Ø 1. 0 mm S 2 -Glass braided Or according to FRESCA 2 choice Q 3 -2012 RMC#1 coil 2 PIT 40 * Ø 1. 0 mm S 2 -Glass braided Or according to FRESCA 2 choice Q 4 -2012 Conductor availability? RMC#2 coil 1 RRP 40 * Ø 1. 0 mm S 2 -Glass braided Or according to FRESCA 2 choice Q 1 -2013 RMC#2 coil 2 RRP 40 * Ø 1. 0 mm S 2 -Glass braided Or according to FRESCA 2 choice Q 1 -2013 Conductor availability? April 24 th 2012 22 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology Next RMC Coils Production

• 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 Nb 3 Sn 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 • SMC#4 and SMC#5 will be used to compare PIT and RRP cables April 24 th 2012 23 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology Conclusions

• 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 design and fabrication drawings are ready • RMC structure delivery scheduled for September 2012 • First RMC coil using a copper cable will be wound Q 3_2012 • First RMC cold powering test with a single coil configuration is scheduled for end of 2012/early 2013 April 24 th 2012 24 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology Conclusions

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 April 24 th 2012 25 J. C. Perez TE/MSC-MDT Eucard-WP 7 -HFM 9 th Collaboration Meeting at Warsaw University of Technology SMC/RMC collaboration team