11-T Dipole Collaboration Review Cold Mass Fabrication and Tooling Procurement

11-T Dipole Collaboration ReviewCold Mass Fabrication and

Tooling Procurement

F. Savary, with contributions from B. Auchmann, E. Grospelier, S. Izquierdo Bermudez,

M. Karppinen, F. Lackner, J.S. Murtomaki, H. Prin27 September 2012

MSC-LMF

2

OUTLOOK• From short models to full-scale prototypes/magnets• The Large Magnet Facility at CERN• Welding of the shrinking cylinder• Tooling procurement• Staffing plan• Conclusions

Cold Mass Fabrication and Tooling Procurement - FSY27/09/2012

Cold Mass Fabrication and Tooling Procurement - FSY 3

FROM SHORT MODELS TO FULL-SCALE PROTOTYPES/MAGNETS

27/09/2012


Milestones (short model – long prototype)• Final design of the short model cold mass, 2 m (collared coil

assembly in yoke + shells + end plates)• 2-1 Demonstrator Magnet Model 1 FNAL (2 m)• 2-1 Demonstrator Magnet Model 2 CERN (2 m)• Preliminary design of prototype CM assembly (6.18 m)• Dummy cable delivery (a unit length of bare Cu cable &

another one insulated) to make 1st practice coil in Cu• Final design of short model CM validated by short model

program (2 m) + 1st long practice coil in Cu• Real cable delivery (for prototype CM assembly, including

practice coil in Nb3Sn)• Final design review of prototype CM assembly (6.18 m)• Design and procurement of tooling for prototype CM• Prototype collared coil assembly• Prototype CM assembly and cryo-magnet• Cold test27/09/2012

: Q4-12

: Q3-13: Q4-13: Q3-13: Q3-13

: Q1-14

: Q1-14

: By mid-14: Started: Q1-15: Q3-15: Q4-15


THE LARGE MAGNET FACILITY AT CERN

27/09/2012


Where?

27/09/2012

180

• Meyrin site, French territory

• B-180– ~ 5500 m2

– Cm area with 40 t crane– Cc area with 15 t crane

• B-183– ~ 1500 m2

– 30 t crane– Bb, machine shop and

storage

183


Overview of the Large Magnet Facility• A production line is available for horizontal assembly, in B-180

– Presently for NbTi magnets, nearly fully operational (a Q5 was assembled recently, and a MB is under construction)

– From cable insulation to finished cold mass assembly– Coil length up to 14.5 m– Cold mass diameter up to 630 mm without major difficulty (welding-

press currently equipped for 570 mm cold masses) – Including a dedicated area for the fabrication of bus bars (+

development of splices) in B-183– 29 dipole and 7 quadrupole cold masses, removed from the machine (33

from sector 34), were repaired in B-180• Plan to adapt tooling for Nb3Sn magnets (see later in this ppt)• A vertical assembling tour is also available in B-181

– For quadrupoles with inertia tubes concept– Fully operational (a Q7 was made there, now under finishing in B-180)

27/09/2012

Cold Mass Fabrication and Tooling Procurement - FSY 827/09/2012

180


181


WELDING OF THE SHRINKING CYLINDER

27/09/2012


Cradle design and coil stress• Requirements regarding the coil / shell stress (1-1)

– Coils in compression and shells in tension at cold & full current

– DESIGN = 160 MPa (shell stress at RT after welding)– Avoid overstressing the coils during the magnet construction

ALLOWABLE = 140 MPa– Close the yoke gap after welding of the shells, ensure that is stays

closed at cold and full current

Values are determined for a shell thickness of 12 mm

27/09/2012

Load condition Coil stress [MPa] Shell stress in [MPa]RT, after collaring 75 -RT, after welding the shells < 140 1601.9 K < 140 < RP0.2

1.9 K, 11T < 140 < RP0.2


Structural analysis was performed in order to:

• Verify if the cradle approach can introduce sufficient pre-stress in the shells

• Predict the achievable pre-stress in the shell based on new welding techniques (Welding -> thermal contraction -> pre-stress)

• Estimate the resulting pre-stress in the coil in each load-step• Compare the results when introducing thicker shells

27/09/2012

• The load steps are as follows:

Assembly at RT

Cradle loading 375 t/m

Welding contraction

Afterwelding-press

opening

Cooling to 1.9 K

1.9 K11 T

1.9 K12 T


In order to estimate the effect of friction between shell and yoke two approaches were considered:1. Introducing a friction based contact in ANSYS2. Bonding the nodes over a 90˚ surface on the shell

The shell pre-stress in ANSYS is implemented as a displacement constraint in the shell

Closed gap is resulting in a reaction force over the entire gap height

Coil pre-stress due to the various load-steps

2D Model - ANSYS

90˚ Bonded surface

The results presented are for the frictionless and bonded contact approachesThe implementation of pure friction would require the implementation of further load steps for realistic static to kinematic friction transition

Model


0. Assembly at RT

1. Cradle loading 375

t/m

2. Welding contraction

3. After welding

4. Cryo 5. 11-T 6. 12-T0.0

50.0

100.0

150.0

200.0

250.0

300.0

350.0

400.0

12mm frictionless 190MPa

12mm bonded 190MPa


12mm bonded 140MPa

Load steps

σavg

(MPa

)

Gap closed through all load steps !

Weld shrinkages (mm):(Applied displ constraints)

Frictionless 190MPa: 0.46 Bonded 190MPa: 0.34Frictionless 140MPa: 0.33 Bonded 140MPa: 0.26

The maximum that we can possibly achieve

The minimum required to keepthe gap closed after welding

Stress in the shell (average), 12 mm thickness


0. Assembly at RT

1. Cradle loading 375

t/m

2. Welding contraction

3. After welding

4. Cryo 5. 11-T 6. 12-T0.0

50.0

100.0

150.0

200.0

250.0

300.0

350.0

400.0

15mm frictionless 190MPa15mm bonded 190MPa15mm frictionless 115MPa15mm bonded 115MPa

Load steps

σavg

(MPa

)

Gap closed through all load steps !

Weld shrinkages (mm):(Applied displ con-straints)


The maximum wepossibly can achieve

The minimum required to keepthe gap closed after welding

Stress in the shell (average), 15 mm thickness


Back in 2002 …

27/09/2012

30 b

ar

50 b

ar

100

bar

150

bar

200

bar

250

bar

270

bar

Ap

STT

Ap

1 M

IG

Ap

2 M

IG

Ap

3 M

IG

0 A

p S

ou

0 A

v M

od

70 b

ar M

od

0 A

p 70

140

bar

Mod

0 A

p 14

0

210

bar

Mod

0 A

p 21

0

280

bar

Mod

0 A

p 28

0

0 A

v Te

st P

1 ba

r

2 ba

r

5 ba

r

10 b

ar

15 b

ar

20 b

ar

23 b

ar

30 b

ar T

P

23 b

ar 2

20 b

ar 2

15 b

ar 2

10 b

ar 2

5 ba

r 2

Fina

l Ap

TP

0

20

40

60

80

100

120

140

160

180

Evolution of average tensile stress in prototype MBP2O2

Manufacturing step

Azi

mut

hal s

tres

s in

shr

inki

ng c

ylin

der [

MPa

]

Loading se-quence

Fillingpasses

Rootpass

Final pressure test

Precondition:Yoke-gap

closed

• Welding of the LHC main dipole shells

60.070.080.090.0

100.0110.0120.0130.0140.0 Coil max stress (Shell 12 mm)


12mm bonded 190MPa


12mm bonded 140MPa

Load steps

σmax

(MPa

)



60.070.080.090.0

100.0110.0120.0130.0140.0

Coil max stress (Shell 15 mm) 15mm frictionless190MPa

15mm bonded 190MPa


15mm bonded 115MPa

Load steps

σmax

(MPa

)



27/09/2012 Cold Mass Fabrication and Tooling Procurement - FSY 17

Stress in the coilsCo

llarin

g


The Fjellman press

• How it was before refurbishment

27/09/2012


The Fjellman press: Status• Length: 2.25 m effective• Load capacity: 330 t/m, or 750 t overall• Number of jacks (top): 28 jacks

6 independent circuits, see layout

• Reconstruction plan:– Extension and reinforcement work is ongoing– Cradles ordered, delivery expected beginning of November 2012 – Hydraulics ordered, delivery expected end of November 2012– Welding equipment (power source, welding torch carrier and traveling

chariot) will be rented for the first mock-up– Welding press operational first week of December 2012– Welding of the first mock-up scheduled in the middle of Dec. 2012

27/09/2012


360

222

209

209

Reinforcement plates

• Cradle design for the 534 mm diameter single aperture magnet• Top and bottom cradles need to be different: the bottom one has a

slightly larger diameter

• Main frame currently under machining at an external company

• The loading/unloading mechanism will be based on a hydraulic lifting system

• 6 hydraulic circuits, surface of main plate = 2520 x 850 mm• Existing hydraulic cylinders will be maintained and reused• Semi-automated control system will be implemented• Welding equipment from the company EWM will be tested during

the first welding trials in Dec. 2012

Main frameStatus, cont’d

2160

Cold Mass Fabrication and Tooling Procurement – FSY 21

Mock-up, to check whether we can build pre-stress

27/09/2012

1-in-1 Mock-up

Existing CTF yoke • Rout = 255 mm• Length = 500 mm• Yoke gap shimmed in

order to have 0.1 mm on outer and no gap on inner radial position

Shell • Material: AISI 304 L (RP0.2 = 220

MPa) • Thickness: 12 mm thickness

(fallback with 15 mm shells)• Length: 1 m

Aluminium cylinder will be used as dummy collared coil• Rout = 98 mm• Rin = 60 mm• Radial shim 0.6 mm thickness +/- 30 degrees around the mid-

plane

Aluminium gap controller(no horizontal contact between gap controller and yoke)

Measurements:• Global stiffness of the assembly, spring constant• Stress in shells (strain gauges, at the inner and outer surface

to determine tensile and bending components)• Yoke gap• Lateral gap between upper and lower shells FE model from B. Auchmann

Equivalent stress distribution using the

existing CTF yoke and an aluminium cylinder to

simulate the collared coil

Preliminary welding trials were done on plates

1 2 3

500 mm25

0 m

m

12 mm

250 mm

𝛼 1

𝛼 2

GAP

Root

face

50 m

m

(Datum points to measure the shrinkage)

Aim: Determine welding parameters and details of the chamfer in order to get as large welding shrinkage as possible

Welding parameters:- Material: AISI 304 L- Filler metal: 1.4453 (BOEHLER ASN5IG)- Shielding/Backing gas: Argon

Welding process:- TIG + MIG (CERN Main Workshop, EN-MME)- Cold Arc (external company, EWM)


Welding Process

Backing strip?

GAP (mm)

Root face (mm)

Average Shrinkage (mm)

CERN MW

1 4xMIG Yes 3 2 25 25 0.9

2 3xTIG + 3xMIG No 2.15 2 50 25 1.5

3 3xTIG + 4xMIG Yes 3.85 1.8 50 25 1.6

Company EWM

1 1 + 4 Cold Arc No 4 2 30 30 1.70

2 1 + 3 Cold Arc No 4 1.5 25 25 1.60

3 1 + 4 Cold Arc No 3 1.5 25 25 1.45

4 1 + 4 Cold Arc No 3 2 25 25 1.45

5 1 + 3 Cold Arc No 3 2.2 25 30 1.70

6 1 + 3 Cold Arc No 3 2.0 25 25 1.50

7 1 + 4 Cold Arc No 3 2.0 25 25 1.35

8 1 + 4 Cold Arc No 3 2.0 30 30 1.43

1 + 4 Cold Arc No 3±0.7 2.2±0.5 29±1 Mock up

Preliminary welding trials on plates: summary


Welding of 1-in-1, and 2-in-1 models

27/09/2012

Outer diameter: 534 mm (for 12 mm shells) 580 mm (for 15 mm shells)

Total length: 2168 mm (t.b.c.) 2130 mm (t.b.c.)

Expected date:1-in-1 #1: Q2-20131-in-1 #2: Q3-2013

1-in-1 #3: as neededFNAL 2 in 1 Demonstrator (Q3-2013)CERN 2 in 1 Demonstrator (Q4-2013)

Shells made of AISI 316LN (RP0.2 = 290 MPa)

1-in-1 2-in-1


TOOLING PROCUREMENT

27/09/2012


Large size tooling procurement - preparation• Reaction furnace

– Market Survey done– IT-3861/TE launched in the end of September 2012– Contract signature expected in December 2012– Delivery to CERN expected in last quarter of 2013

• Impregnation chamber– Market Survey, MS-3898/TE, launched on 14 September 2012– IT to be launched in the middle of November 2012– Contract signature expected in late January 2013– Delivery to CERN expected in last quarter of 2013

• Winding machine available– Needs to be adapted: length, winding mandrel, integration of additional spool,

automat programming• Curing-press available, curing molds to be developed• Welding-press

– New welding equipment and simpler seam tracking system will be integrated after validation of the process with the 500-mm long mock-up

27/09/2012


Preparation work for winding• Plan to launch in early October tooling

modification (design then, construction) to allow fabrication trials (this is NOT the first practice coil made of Cu)

• Aim to resolve major issues at an early stage

27/09/2012

• Shorten the winding machine from 10 to 6 m

• Integrate a suspension for the second spool

• Fabricate winding mandrel and ancillaries

From “short”

To “long”

B-927

B-180


STAFFING PLAN

27/09/2012


The context … and the solution under preparation• LMF staff (50)

– 16 CERN staff + 1 fellow– 33 FSUs

• Most in the LHC tunnel for LS1 from April 2013 to June 2014– Most already busy with the preparation work

• CERN launching IT-3895/TE for service contracts to selected companies, specialized in the design and construction of sc magnets

– Envelope of 6 FTE, start progressively according to needs as from second quarter of 2013

– Typically 3 teams constituted of 1 academic engineer or physicist, 1 technical engineer or higher technician, and 1 experienced practitioner, with room for different scenarios

– To work together with CERN staff, and prepare industry for technology transfer at an early stage of the project

27/09/2012


CONCLUSIONS

27/09/2012


• Preparation of tooling has started, mainly the short welding-press, compatible with the design of the long welding-press

• Procurement process of long lead time tooling has started: reaction oven, impregnation system/chamber

• Plan to start very soon the modifications of the winding machine, and the execution of winding trials

• Plan to populate the magnet facility during LS1 has started• Regarding the cold mass assembly drawings (6.18 m long

prototype): all needs to be done, even if important input is available for the active part (from short model program)

27/09/2012


SPARE SLIDE

27/09/2012


Back in 2002 …

• Welding of the LHC main dipole shells27/09/2012

Welding process Av. tensile stress in shrinking cylinder

MBP2N1 Root pass MIG Filling passes 2 TIG + 3 MIG

178 MPa

MBP2N2 Root pass MIG Filling passes 3 MIG

140 MPa

MBP2O1 Root pass MIG Filling passes 3 MIG

143 MPa

MBP2A2 Root pass MIG Filling passes 3 MIG

140 MPa

MPP2O2 Root pass STT Filling passes 3 MIG

156 MPa

MBP2A1 Root pass STT Filling passes 3 MIG

155 MPa

Documents

11-T Dipole Collaboration Review Cold Mass Fabrication and Tooling Procurement