US LHC Accelerator Research Program bnl fnal lbnl

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US LHC Accelerator Research Program bnl - fnal- lbnl - slac Nb 3 Sn

US LHC Accelerator Research Program bnl - fnal- lbnl - slac Nb 3 Sn Cable and Insulation for LARP High-Gradient Quadrupole Magnets D. R. Dietderich Lawrence Berkeley National Laboratory Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

Outline of the Presentation • Cabling Philosophy for Rutherford Cables – 1 Pass and

Outline of the Presentation • Cabling Philosophy for Rutherford Cables – 1 Pass and 2 Pass cables • Cored cables • R&D to reduce HQ cable dimensions – With wire diameters of 0. 778 mm and 0. 800 mm • Insulation development Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN LARP TQ cable

LARP Cable Fabrication – 2 Pass • 2 pass process was developed to reduce

LARP Cable Fabrication – 2 Pass • 2 pass process was developed to reduce dimensional changes of a cable during coil processing and reaction – A cable is fabricated oversize in thickness, annealed (200 C for 2 -4 hrs), and re-rolling to final thickness. • The anneal reduces the residual stress in the cable and the cable typically shortens by 0. 20 – 0. 25%. • Very important -- Cable is permitted to get wider during the second pass – 2 nd pass roll are~ 50 -100 microns wider • • If a cable is too narrow -Strain localized to 3 strands at the edge of a cable due to friction between rolls and strand Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

LARP Cable Fabrication – 1 Pass • 1 pass process has been developed for

LARP Cable Fabrication – 1 Pass • 1 pass process has been developed for adding stainless steel (SS) cores to cables – Strand is annealed (190 C for 4 hrs) prior to cabling Un-reacted Reacted wire – Cable is made in 1 pass to final dimensions • Due to mechanical differences between the strand the SS core a 2 pass process is not possible. • However, other core materials such as Sglass tape or Mg. O paper tape could be made in 2 -pass. Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN Ductility check

2 Pass Cable with Mg. O Paper & S-glass Cores Nov. 16, 2011 D.

2 Pass Cable with Mg. O Paper & S-glass Cores Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

Cored Cables (HQ-1012) Used in HQ Coil 12 • HQ cable 1012 (old cable

Cored Cables (HQ-1012) Used in HQ Coil 12 • HQ cable 1012 (old cable parameters) Mandrel with slot – 35 strands with diameter of 0. 80 mm for adding a core – 1. 44 mm mid-thickness, • Did not increase mid-thickness with of core addition – 15. 1 mm wide – 0. 75 deg. Keystone angle – 8 mm wide, 0. 025 mm thick stainless steel core • Biased to thick edge of cable – Core biased toward thick edge of the cable • No fabrication issue with the addition of a SS core • Addition of the core did not degrade the Ic – Measurements show a reduction of 3 -5 % which is typical for an HQ cable without a core Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

Objective of Cable R&D • To permit the use of existing HQ tooling –

Objective of Cable R&D • To permit the use of existing HQ tooling – The cable dimensions needed to be reduced to: – Provide more space azimuthally (i. e. thinner cable) – Provide more radial space (i. e. narrower cable) • Cable R&D targets dimensions: – Reduce HQ cable thickness by 65 -100 microns • To 1. 375 mm - 1. 340 mm – Width target is < 15 mm (14. 7 mm -15 mm) • Accommodates dimensional changes of cable during reaction • Thicker insulation or more insulation between layers and tooling – Keystone angle un-changed at 0. 75 deg. Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

HQ Cable R&D to Reduce Cable Size • The next slide shows the thickness

HQ Cable R&D to Reduce Cable Size • The next slide shows the thickness and width of several cable samples – Cable 1014 • 34 strands with a diameter of 0. 80 mm – Cable 1015 • 35 strands with a diameter of 0. 778 mm • “Blue Box” denotes the target parameters needed to accommodate the cable dimensional changes in the present tooling. – The box with dashed lines are the parameters deduced from R&D on TQ and LQ coils • “Red Circle” denotes the new HQ parameters with the 0. 778 mm diameter strand Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

HQ Cable Parameters of R&D Cables Old HQ cable HQ Box New HQ cable

HQ Cable Parameters of R&D Cables Old HQ cable HQ Box New HQ cable Zone with Too much damage Nov. 16, 2011 TQ LQ D. R. Dietderich Hi Lumi/LARP CM 17 CERN

Critical Current Cable 1014 with 34 strands and wire diameter 0. 80 mm Un-deformed

Critical Current Cable 1014 with 34 strands and wire diameter 0. 80 mm Un-deformed Round Wire Extracted Strands Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN A. Gosh (BNL) A. Godeke (LBNL)

RRR 1014 – 0. 80 mm wire Un-deformed Round Wire Nov. 16, 2011 D.

RRR 1014 – 0. 80 mm wire Un-deformed Round Wire Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

Critical Current Cable 1015 & 1017 with 35 strands and wire diameter 0. 778

Critical Current Cable 1015 & 1017 with 35 strands and wire diameter 0. 778 mm 1 st Production cable 1017 Extracted strands Un-deformed round 650 C wire for 72 h 665 C for 48 h 36 strands Nov. 16, 2011 Un-deformed Round Wire D. R. Dietderich Hi Lumi/LARP CM 17 CERN

RRR 1015 – 0. 778 mm wire Nov. 16, 2011 D. R. Dietderich Hi

RRR 1015 – 0. 778 mm wire Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

Cable 1015 Sections I & L 1015 -I • No significant subelement damage is

Cable 1015 Sections I & L 1015 -I • No significant subelement damage is observed in the wire cross-sectional images Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

Cable -- Summary • A stainless steel core can be added to the standard

Cable -- Summary • A stainless steel core can be added to the standard HQ cable without significant loss of critical current • Standard HQ cable with 0. 80 mm diameter wire could have be decreased in thickness and width to meet the target parameters (HQ box) – However, the risk of damaging to the strand was considered to great with addition of a corfe – i. e. reduced processing margin. • New HQ cable uses a 0. 778 mm diameter strand to achieve the new cable parameter • The critical current variation in cable 1015 is not understood but could be due to: – Sample handling while preparing for Jc testing. – Or localized damage in some strands during cabling. – Suggests that a cable testing facility is needed for accurate cable critical current measurements. • RRR was reduced slightly by cabling Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

Insulation Braided onto Cables New England Wire S-glass with 636 sizing TQ/LQ Cable 10

Insulation Braided onto Cables New England Wire S-glass with 636 sizing TQ/LQ Cable 10 mm wide Braid angle 64 deg. New England Wire S-glass with 933 sizing HQ Cable 15 mm wide Braid angle 55, 60, 64 deg. Pitch Angle Thickness 55 o 0. 103 mm 60 o 0. 109 mm 64 o 0. 114 mm Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN A. Ghosh - BNL

Tape Winding • LBNL having vendor fabricate tape winding machine – Demo video •

Tape Winding • LBNL having vendor fabricate tape winding machine – Demo video • FNAL has an established process with Eglass – 2 layers – Thickness ~0. 100 mm Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

Summary – Insulation Options • Braided insulation onto cable – Primary option – New

Summary – Insulation Options • Braided insulation onto cable – Primary option – New England Wire • S 2 -glass with 636 and 933 sizing – Requires cleaning of insulated cable – thickness of 0. 103 -0. 114 mm • Plan to develop process for fibers with Silane sizing – Revolution Composites • S 2 -glass – Also makes sleeve • New company but with staff from EDO Fiber Innovations • Tape options – Second option – E-glass 2 layers can produce 0. 100 mm • Contains boron – could be an issue. – S 2 -glass tape • Two layers of tape is > 0. 100 mm (0. 125 -0. 150 mm) – Consider making braided insulation thicker to match • Consider single layer of tape 0. 100 mm thick Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

Extra slides Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

Extra slides Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

R&D to Reduce HQ Cable Dimensions • New cable parameters: – Mid-thickness – Width

R&D to Reduce HQ Cable Dimensions • New cable parameters: – Mid-thickness – Width – Keystone angle 1. 375 mm 14. 80 mm 0. 75 deg. from 1. 44 mm from 15. 10 mm Unchanged • New cable designs will provide more space in tool for cable dimensional changes – Have made the first production cable 1017 with new parameters • HQ coil 14 has been fabricated and is ready to test in a mirror. – Have just made a cored cable with the new cable parameters with a strand diameter of 0. 778 mm. • Coil winding with the cored cable was OK – However, popped strands were produced going around the pole • They are pushed back into position and winding continues – Planning to cut HQ coil 12 into sections for inspection. Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN

1 Pass Cable with Stainless Steel Core Nov. 16, 2011 D. R. Dietderich Hi

1 Pass Cable with Stainless Steel Core Nov. 16, 2011 D. R. Dietderich Hi Lumi/LARP CM 17 CERN