The 2 nd workshop on SCRF Cavity Technology

The 2 nd workshop on SCRF Cavity Technology and Industrialization for the ILC @Chicago, July 2011 Industrialization Studies in the KEK Cavity Fabrication Facility (CFF) H. Hayano 07242011 S. Yamaguchi, K. Ueno, T. Saeki, H. Inoue, Y. Ajima, Y. Watanabe, K. Enami, S. Koike, S. Kato, E. Kako, Y. Yamamoto, A. Yamamoto; KEK 1

KEK Cavity Fabrication Facility(CFF): main R&D KEK initiative on mass-production technology R&D in CFF KEK also like to invite industry participation in CFF Center cell R&D ✓ EBW Quality Control Technology ( multi-dumbbell, multi-cavity Jigs for EBW ) it will start soon. End-group R&D ✓ Deep Drawing Technology ✓ Fine-blanking (Water-jet cut) and Press-forming Technology ( End-group Jigs for EBW ) it will start soon. 2

KEK Cavity Fabrication Facility 19 m x 14 m clean room STF ATF Building inside Chemical Room Press Machine EBW Trimming Machine KEK Cavity Fabrication Facility Inspection area Plant clean room Crane range 3

EBW delivery on April 12, 2011 12 th April 2011 4

Main Machines in the facility EBW SST EBOCAM KS-110 – G 150 KM Chamber (Stainless Steel chamber) Press AMADA digital-survo-press SDE 1522 150 t, 50 stroke/min, 225 mmstroke Tape-cut Ceremony on July 13, 2011 for EBW operation start. Trim MORI VKL-253 Vertical CNC lathe Chemi-room 5

Center Cell Fabrication R&D KEK 9 cell cavity #0 (w/o HOM couplers) fabrication 6

Press, Trim, EBW R&D before KEK-EBW delivery by using EBW Job-shop Cell Press at KEK BCP at KEK Trimming at KEK Stiffener Press at KEK EBW at Tosei-electrobeam co. , Tokyo　 (SST-EBW) 7

Dumbbell EBW at Job-shop (Dec. 2010 – Feb. 2011) Total 13 dumbbells were fabricated. 8 of them went to cavity fabrication 8

Stiffener Insertion and EBW stretching of dumbbell EBW setting stiffener insertion Stiffener EBW after insertion After Stiffener EBW 9

2 - Dumbbell EBW at Job-shop (Dec. 2010 – Feb. 2011) 10

4 – Dumbbell, 8 - Dumbbell EBW at Job-shop (June. 2011 – July 2011) Beam 30 June 2011 6 July 2011 Beam 8 July 2011 11

8 - Dumbbell EBW-Seam inspection Center cell equater: typical seam Center cell equater: seam end * End-group fabrication will be done in September – October, 2011, right after delivery of Nb pipes. KEK –EBW machine will be used there. 12

End Group Fabrication R&D 13

KEK-End-Group, KEK-HOM-coupler At First, we started HOM coupler fabrication study (1) Deep Drawing of HOM-cup, (2) Cut-out of holes, or Burring of holes. (3) Develop cost effective shape of tuning knob. (4) Press cut-out from thick plate, (5) Press cut-out of slope region, (6) Press forming into design shape 14

One press-action Deep drawing First step study : Using existing press-setup, 1. 5 mm Nb sheets were deep-drawn into cup, by one press-action. Blank diameter: 120 mm Inner diameter : 40 mm Cup height : 65 mm 15

HOM-cup Tuning-Knob forming First step study : Using existing press-setup, deep-drawn cup bottom shape and knob were formed, by two press-action. Knob: 10 mm diameter, 6 mm height 16

HOM Antenna forming Study of Press-forming is underway Water-Jet cut Press forming of Nb HOM Antenna press forming 17

Mass-production R&D, others 18

Conceptual design of automated cell-press KEK-Shinohara Press Idea of Multi-action Press for cell forming *Automated product transfer mechanism in the press machine are also under design. 19

KEK-MHI Estimation of cavity production plant Plant Simulation study using CFF housing area（53 m x 30 m） EBW CP Eddy-current scan reception Press forming stock Inspection Trimming parts delivery shipping of jacketed cavity Stock area Bulk EP anneal Tuning machine AC power area Inspection Assuming Nb plates for cell, fabricated end-group parts are input, 200 working days/year, 2 shifts/day with 30 people times 2 shifts Jacket Max. production rate will be ~530 cavities/year, ~2650 cavities for 5 years. Assuming that final treatment and vertical test will be done in other place. 20

Estimation of cryomodule assembly plant KEK-Hitachi Assembly Plant Analysis using KEK assembly hall area（120 m x 50 m） Cold-mass, thermal shield cavities Assuming VT-passed cavity, fabricated cold-mass parts, vaccum cessel are input, 200 working days/year, 2 shifts/day with 37 people times 2 shifts Vacuum vessel, themal shield Max. production rate will be ~57 cryomodules/year, ~285 cryomodules for 5 years. Assuming that cryomodule power test will be done in other place. 21

Conceptual Design Study Concept of rotational jig for multi-dumbbell and end-parts EBW 22

Conceptual Design Study Concept of EBW rotational jig for multi 9 cell cavities 23

Schedule Plan 24

CFF schedule plan　　for industrialization 2011 7, 8, 9 2012 1, 2, 3 10, 11, 12 4, 5, 6 2013 7, 8, 9 10, 11, 12 4, 5, 6 1, 2, 3 7, 8, 9 EP, VT KEK-#0 w/o HOM EP, VT KEK #1 EP, VT KEK #2 EP, VT 2011 materials procurement KEK #3 2012 materials procurement HPV application KEK #4 EBW fixture development Design of multi-dumbbell fixture HPV inspection operation and upgrade fabrication Design of endgroup EBW fixture KEK #6 operation and upgrade fabrication operation and upgrade Trim fixture development Design Jacketing KEK #5 fabrication Design of multi 9 -cell cavity fixture EP, VT operation and upgrade fabrication Automated BCP Design fabrication CFF industrial production operation and upgrade Deep-drawing, Forming press development Basic R&D　 Design of pressshape deep drawing jig fabrication operation and upgrade 25 Hayano’s proposal; June 2011

STF Plans for cavity production and test CY 2011 operation disassembly CY 2012 CY 2013 CY 2014 CY 2015 CY 2016 S 1 -Global cryomodule operation finished Start beam operation Phase-2 Injector construction operation Phase 2 Injector part operation as “Quantum-Beam Project” ILC Cryomodule operation 1 st Cryomodule operation Phase 2 CM-1 cryomodule construction STF phase-2 Phase 2 CM-2 construction or cavities replacement of CM-1 4 cavities/year from Industries cavity operation replace Cavity Fabrication Facility Startup & EBW jig construction CFF Industrialization Operational (4 cavities/year) KEK EBW operational 1 st cavity 2 nd cavity, 3 rd, 4 th, …. Cavity Industrialization Start 26

Summary R&D status of KEK Cavity Fabrication Facility Center cell R&D 1. EBW Technology Experience through KEK-#0 9 -cell cavity (w/o HOM) production. 2. By using EBW job-shop, center cell part was finished its fabrication. 3. After Nb pipes delivery, end group fabrication will be done in September – October, 2011, by using KEK EBW. End-group R&D 1. R&D on Deep Drawing Technology, Press forming technology are on-going. 2. Using existing press setup, possibility of end group parts fabrication from Nb sheet and from Nb thick sheet is under demonstration. Mass-production Studies 1. Conceptual Design Studies on Press-forming and EBW is started. 2. Cavity production plant and Cryomodule assembly plant are in study. Cavities by CFF, and cavities from industries, will be tested in cryomodule. 27 End