MANUFACTURING PROCESS VALIDATION AND FACTORY TEST ESS RFQ

MANUFACTURING PROCESS, VALIDATION AND FACTORY TEST ESS RFQ CDR 2 2015 12 08 -09 Bruno POTTIN

TABLE OF CONTENTS 1: Copper + HIP 2: Ancillaries 3: Section manufacturing 4: Brazing process 5: Couplers 6: Tuners 7: Acceptance factory test Bruno POTTIN | PAGE 2

SECTION MANUFACTURING One RFQ section manufacturing’s steps process Bruno POTTIN | PAGE 3

SECTION MANUFACTURING 1 Copper + HIP One RFQ section manufacturing’s steps process 3 Section manufacturing 2 Ancillaries 4 Brazing process Bruno POTTIN | PAGE 4

COPPER AND HIP CEA Saclay/Irfu ESS RFQ CDR 2| 8 -9 Dec 15 | PAGE 5

COPPER AND HIP One RFQ section manufacturing’s steps process Bruno POTTIN | PAGE 6

CHOSEN MATERIAL: CU-OFE • Cu-OFE is chosen for our application (NF EN 13604) • Already used for other RFQ (IPHI, LINAC 4, Spiral 2) • Cu-OFE can be machined and brazed « easily » • Addition of a prevention step: HIP (High Isostatic Pressing) • To avoid porosity / casting defects Example of an porosity in IPHI copper on a brazing plan Bruno POTTIN | PAGE 7

COPPER PROVIDING PROCESS Copper OFE • Chemical composition analysis 3 D forging 5 mm peeling Annealing • • • Delivery in course Grain size Hardness Ultrasonic testing HIP treatment process was validated with mock-up HIP treatment after copper delivery and before starting machining : 920°C - 1020 bars – 2 h Argon gas Call for tender HIP High Isostatic Pressing Order in progress Manufacturing Bruno POTTIN | PAGE 8

HIP TREATMENT MOCK-UP Ø 1 Ø 2 Ø 3 Assembly by brazing HIP treatment 3 holes : 1, 2 and 3 mm diameter Bruno POTTIN | PAGE 9

HIP TREATMENT MOCK-UP Before q After HIP, we have : - Holes disappeared q Metallographic study : - Grain size increase - Low hardness After Bruno POTTIN | PAGE 10

HIP EQUIPMENT HIP treatment in one step for all the sections copper Same copper quality for manufacturing Major vane Minor vane • • • 3 possible levels in the oven Capacity : • 12 major vanes • 18 minor vanes Needed : • 12 major vanes 6 sections (5 + 1 spare) • 12 minor vanes Bruno POTTIN | PAGE 11

ANCILLARIES CEA Saclay/Irfu ESS RFQ CDR 2| 8 -9 Dec 15 | PAGE 12

SECTION MANUFACTURING One RFQ section manufacturing’s steps process Bruno POTTIN | PAGE 13

MAIN TECHNOLOGICAL CHOICES ESS IPHI q Ancillaries : Tuner ports : stainless steel with • copper coating inside and nickel coating outside • Section flanges : stainless steel with nickel coating Pumping grids machined directly on the vane To avoid machining of the pumping grids on the vanes decrease the machining difficulty q Ancillaries : q • § tuner ports § pick up ports § section flanges § pumping grids § a a first correction of the error on the machining of the vanes before brazing by adjusting the penetration of the pumping q Technological problem to braze the stainless steel on the copper module q Brazing copper to copper and stainless steel to copper in 1 step port q • • § IPHI § § § q IPHI 2 brazing steps : Stainless steel to copper for ancillaries Copper to copper for module + ancillaries Using copper No copper coating inside No nickel coating outside No coating simpler Final machining adjustment for brazing on copper Bruno POTTIN | PAGE 14

ANCILLARIES MANUFACTURING Ancillaries manufacturing’s steps process Tridim measurement Leak test Bruno POTTIN | PAGE 15

ANCILLARIES PROCUREMENT : TEST CAVITY q Mock-up validation of brazing ancillaries on copper cavity as RFQ q Brazing section flange q Brazing tuner port q Brazing coupler port q Brazing pumping grid q Brazing pick up port q Validation with leak test and tridim measurements The test cavity is useful for the couplers conditioning Bruno POTTIN | PAGE 16

SECTION MACHINING CEA Saclay/Irfu ESS RFQ CDR 2| 8 -9 Dec 15 | PAGE 17

MAIN TECHNOLOGICAL CHOICES q IPHI’s project : 4 copper parts per section chosen for ESS Machining Assembly Brazing copper parts and ancillaries in vertical position in 1 step Bruno POTTIN | PAGE 18

SECTION MANUFACTURING One RFQ section manufacturing’s steps process Bruno POTTIN | PAGE 19

SECTION MANUFACTURING Manufacturer and process validation 2 major technical phases to be tested in parallel q Step 1 • Qualification of deep drilling and machining technic • Validation of process and manufacturer capacity with his equipment • Ultrasound test and tridim measurement c Ma ng i hin p k-u c mo -up ck mo ling e De ril p d q Step 2 • Qualification of vertical brazing process • Validation of manufacturer brazing process • Tridim measurement and leak test ck-up mo azing Br IPHI Schedule and process adaptation to reach the ESS schedule Bruno POTTIN | PAGE 20

SECTION MANUFACTURING To start the third step, the steps 1 and 2 must be done q Step 3 3 • Qualification of a total section manufacturing : Section 1 • Leak test, tridim and RF measurement To start the series production, the step 3 must be validated q Series production • Sections manufacturing : process adaptation with industrial • Following process to optimize the time • Leak test, tridim and RF measurement q Development plan and validation test according to the qualification phase Bruno POTTIN | PAGE 21

SECTION MANUFACTURING VALIDATION One RFQ section manufacturing’s steps process Specific validation operations will be done by CEA or with CEA presence Tridim measurement Tridim and RF measurement Bruno POTTIN | PAGE 22

SECTION MANUFACTURING Brazing Machining Vacuum leak test validation Tri. Dim RF validation Bruno POTTIN | PAGE 23

BRAZING PROCESS CEA Saclay/Irfu ESS RFQ CDR 2| 8 -9 Dec 15 | PAGE 24

SECTION MANUFACTURING One RFQ section manufacturing’s steps process 2 different brazing processes Bruno POTTIN | PAGE 25

2 BRAZING PROCESSES Two different brazing processes used Ancillaries manufacturing Sections manufacturing • • Small pieces (small oven) Stainless steel-copper brazing without coating R&D step to industrialize the manufacturing Many components Large pieces (big oven) Copper-copper brazing Vertical brazing according to big geometrical movement due to thermal expansion phenomena The process (not the same brazing) and the equipment (oven size) are different, not the same resources 2 procurements to reach the ESS schedule Bruno POTTIN | PAGE 26

SECTION MANUFACTURING One RFQ section manufacturing’s steps process Ancillaries adapted for brazing • • • Tridim measurement to check the section RF measurement Brazing Leak test RF measurement Tridim measurement Bruno POTTIN | PAGE 27

COUPLERS CEA Saclay/Irfu ESS RFQ CDR 2| 8 -9 Dec 15 | PAGE 28

MAIN TECHNOLOGICAL CHOICES q RF loops (coupler : window + loop) • Same technology as SPIRAL 2 (just adaptation) • Possible use of simple coaxial disc RF window smaller and lighter than waveguide window (easier installation) SPIRAL 2 • RF losses smaller than with iris+ridge (power budget) • Faster adjustment and adjustment flexibility (RF tuning success) Bruno POTTIN | PAGE 29

COUPLER MANUFACTURING q Qualification PHASE • Step 1 : RF window o Machining and assembly copper-ceramic process o Ti. N coating o Leak test o RF test before and after Ti. N coating • Step 2 : double cooling circuit o Machining and assembly process o Leak test o Tridim measurement q Manufacturing of 3 couplers Bruno POTTIN | PAGE 30

COUPLER TEST VALIDATION Conditioning of the 3 couplers with the test cavity and the pulsed klystron in the dedicated bunker. Coupler will be conditioned until 1 MW peak power in travelling wave Bruno POTTIN | PAGE 31

TUNERS CEA Saclay/Irfu ESS RFQ CDR 2| 8 -9 Dec 15 | PAGE 32

MAIN TECHNOLOGICAL CHOICES ESS IPHI q Adjustement tuners • To do RF tuning q Final tuners for operation • the same dimension q Adapted chock • The correct thickness for each position along the RFQ • Machining delay between adjustment and operation q Impossibility to change the tuners penetration q Adjustable tuners • Same geometry during adjustment and operation (same perturbation) • Definitive position just after adjustment • No delay of machining between adjustment and final position • Adjustment possible in operation or after a transport Bruno POTTIN | PAGE 33

TUNER MANUFACTURING q One prototype with 2 steps • Step 1 o Bellows qualification after a thermal treatment according to the brazing process with a multi traction test o Validation of the welding • Step 2 o Prototype manufacturing o Technological choices validation o Schedule adaptation for series production q Qualification of the mechanical comportment under pressure with the test cavity Bruno POTTIN | PAGE 34

FACTORY ACCEPTANCE TEST CEA Saclay/Irfu ESS RFQ CDR 2| 8 -9 Dec 15 | PAGE 35

MANUFACTURING TRACKING q We will follow each step of manufacturing with presence, measurement, report… • Processes and methods used for manufacturing (deep drilling, machining and brazing) • Operating conditions • Tools for handling and manufacturing • Stabilization for machining (T°, power supply, vibration, calibration, maintenance, oil type …) • • Thermal treatment and brazing : oven characteristics and temperature curve • Storage for the delivery but also during machining • Technical specifications to sub-contractors • … Cleaning process Bruno POTTIN | PAGE 36

LEAK TEST Vacuum leak test validation According to the ESS handbook q Contract approach: We specify this requirement in specifications : During the vacuum test, every leak over 10 -10 mbar. l/s must be repared q Technologic approach: Study of the leak’s impact (Vacuum, RF…) ESS-CEA analysis Repair or not? Repair consequences : risks, cost and delay It’s a choice between a slightly degraded component or to repair with risks

OTHER ACCEPTANCE TESTS Tridim measurement • Dimension validation • Displacement qualification Tuning RF measurement • Cavity RF characteristics validation

THANK YOU CEA Saclay/Irfu ESS RFQ CDR 2| 8 -9 Dec 15 | PAGE 39

THE ESS RFQ MECHANICAL DESIGN The ESS RFQ: q 5 x Sections (L= 0. 92 m) for a total length = 4. 58 m q 2 x Vacuum ports per quadrant and per section except on S 3 (hosting the 2 RF couplers) 32 q 3 x 80 mm-diameter pistons per quadrant and per section acting as tuners 60 q Pick-up ports 28 q 8 x 10 mm-diameter cooling channels per section (variable length) q RFQ in Cu. C 2 and Flanges in stainless steel S 5 S 1 S 2 S 3 S 4 40 mm Cooling channels Global Schematic view of ESS RFQ Transversal view of the RFQ across the tuners View of the end section of the RFQ with the tuning rod for a quadrant Bruno POTTIN | PAGE 40