MQXFA Magnet Production in the US

MQXFA Magnet Production in the US

Giorgio Ambrosio,

with contributions from the whole MQXFA team

Acknowledgement

▪ US HL-LHC Accelerator Upgrade Project (AUP)▪ BNL: K. Amm, M. Anerella, A. Ben Yahia, H. Hocker, P. Joshi, J.

Muratore, J. Schmalzle, H. Song, P. Wanderer

▪ FNAL: G. Ambrosio, G. Apollinari, M. Baldini, J. Blowers, R. Bossert, R. Carcagno, G. Chlachidze, J. DiMarco, S. Feher, S. Krave, V. Lombardo, C. Narug, A. Nobrega, V. Marinozzi, C. Orozco, T. Page M. Parker, S. Stoynev, T. Strauss, M. Turenne, D. Turrioni, A. Vouris, M. Yu

▪ LBNL: D. Cheng, P. Ferracin, L. Garcia Fajardo, E. Lee, M. Marchevsky, M. Naus, H. Pan, I. Pong, S. Prestemon, K. Ray, G. Sabbi, G. Vallone, X. Wang

▪ NHMFL: L. Cooley, J. Levitan, J. Lu, R. Walsh

▪ CERN: HL-LHC Project▪ A. Ballarino, H. Bajas, M. Bajko, B. Bordini, N. Bourcey, S. Izquierdo

Bermudez, H. Felice, S. Ferradas Troitino, L. Fiscarelli, J. Fleiter, M. Guinchard, O. Housiaux, F. Lackner, F. Mangiarotti, A. Milanese, P. Moyret, J.C. Perez, H. Prin, R. Principe, E. Ravaioli, T. Sahner, S. Sequeira Tavares, E. Takala, E. Todesco

2G. Ambrosio - MQXFA Magnet Production in the US

Conductor Procurement & QC

• Conductor delivery:• ~90% conductor received (out of 2500 km, including LARP proc.)

• Last shipment expected in February 2022

• Order for additional conductor (8 cables = 160 km) is in progress

• Issues and audits during fabrication:• June 2020: abrupt shift in RRR (but still well above spec)

➔ COVID production review: some corrections, continued monitoring

• March 2021: loss of test agreement between supplier and verification ➔ 100% V testing implemented: partial recovery of test agreement

• June 2021: process shift to lower Ic (still well above spec) without recovery of other shifts. Outliers in several statistical controls➔ (1) 1-day production stand-down: multiple CAPAs, some related to COVID

➔ (2) full audit Aug 2nd: most root causes found; additional monitoring in place

• Test agreement has recovered; tracking possible raw material shift

• Some spools that were reworked received extra lubricant, and impacted cable stability

• Strand verification, Cable qualification & Witness Sample tests are on schedule


Cable Fabrication & Insulation


▪ Cable Fabrication Status:▪ Fabricated:

▪ Bare cable up to #84

▪ Insulation braiding up to #78

▪ Completed QC up to #74

▪ To be fabricated:

▪ 20 cables (up to 104)

▪ Milestones and yield:▪ 74% complete

▪ Yield is 92.2% (3 rejected, 6 on-hold), vs. 90% assumed

▪ Cables on-hold because of strand lubrication issue causing cable mechanical instability

▪ Exploring cable cleaning to improve mechanical stability of cables on-hold

More details on Thursday in “Mechanical stability of cables” by M. Naus

Coil Parts Procurement


MQXFA coil part procurement is in final phase:

▪ Pole Parts▪ Order for 12 sets was placed with the estimated delivery date Dec. 31, 2021

▪ Last order for 10 sets is in preparation process and will be placed by the end of November.

▪ Includes 6 additional sets

▪ End Parts▪ Order for 12 sets was placed with the estimated delivery date Dec. 31, 2021

▪ Last order for 10 sets is in preparation process and will be placed by the end of November.

▪ Includes 6 additional sets

▪ Plasma coating to be completed by September 2022

▪ All CERN provided parts have been delivered

Coil Fabrication at FNAL & BNL

▪ Coil fabrication is 58% complete (out of 100 coils)

▪ Simple Coil Fabr. yield computation: ▪ In fabrication = 1/3; On hold = ½

▪ * Accepted for shipment; includes QXFP06 (4 m prot.)

▪ ** 1 coil on hold for COVID related issue

▪ Overall Coil Yield after fabrication, magnet integration & magnet vertical test: 83.5%▪ including one coil on-hold after magnet assembly at LBNL

▪ Including one coil rejected after MQXFA07 vertical test

6

Coils at FNAL Coils at BNL Total

Accepted 22* 21 43*

In Fabrication 6 5 11

Rejected 3 2 5

On Hold 4** 2 6**

Total 35 30 65

“Simple” Fabr. Yield 83.9% 88.8% 86.1%

More details on Friday in “Coil fabrication: status at BNL/FNAL”

by J. Schmalzle / F. Nobrega

MQXFA Structure Proc. & Magnet Assembly

7

▪ MQXFA08 is at BNL for vertical test

▪ Assembly of MQXFA09 and MQXFA10 are in progress.

▪ Both assembly lines are fully operational (staggered mode)

▪ MQXFA07 will be disassembled to remove the limiting

coil. It will be reassembled using a new coil and the 3

non-limiting MQXFA07 coils, if they pass inspection tests.

▪ Developing plans to start disassembly after MQXFA09 is shipped

to BNL. To be finalized and approved.

MQXFA shell-yoke assembly in processTwo MQXFA assembly lines at LBNL

More details on Thursday in “Magnet assembly by US-AUP” by D. Cheng

MQXFA Vertical Test (by 302.4)

✓ Operation above 7 TeV

✓ Temperature margin

✓ Excellent memory

J. Muratore et al., “Test Results of the First Pre-Series Quadrupole Magnets for

the LHC Hi-Lumi Upgrade”, IEEE Trans. Appl. Superc. 2021, #4001804

G. Ambrosio - MQXFA Magnet Production in the US

• MQXFA03: 1st pre-series magnet for Q1/Q3

8

MQXFA magnet being

moved to vertical test

station at BNL

MQXFA03/4/5/6 Vertical Test


More details tomorrow in “MQXFA test results” by J. Muratore

MQXFA03/4/5/6/7 Vertical Test


• 4 successful magnets; 5th limited by one coil

More details tomorrow in “MQXFA test results” by J. Muratore

Plans for MQXFA07 ➔ MQXFA07b

▪ MQXFA07 is limited by one coil

▪ It will be dis-assembled in order to remove the limiting coil and replace it with a new coil▪ It will be re-assembled and pre-loaded

▪ It will be tested in Vertical condition

▪ AUP Baseline assumes that 4 magnets out of 20 are going to fail the 1st vertical test

▪ Limiting coil was affected by COVID lockdown▪ 14 weeks stop during fabrication

▪ We are going to perform tomography (CERN lead)


MQXFA03/4/5/6 – Average Straight Section

Harmonics at Nominal

12

Integral harmonics to be

measured in Coldmass

Based on short model

FQ b6 correction

introduced in one coil on

MQXFA04 and all

subsequent coils:

125 um shift toward

midplane

Magnetic shims used to

correct low order

harmonics

▪ Integrated Gradient and Magnetic Length within specs


Vertical Test Summary (by 302.4)

▪ Requirements & Test Goals:

▪ Hold current at nominal current + 300 A

▪ Ramp to/from I_nom at ±30 A/s

▪ 100 A/s ramp down w/o quench (max for power supply)

▪ Temperature margin

▪ Training memory

▪ Magnetic measurements

▪ Splice resistance (large noise fixed since MQXFA04 test)

▪ All electrical requirements

▪ MQXFA03 and MQXFA04 are being used for the

assembly of the 1st LMQXFA Cold Mass


MQXFA03/4/5/6

More details in LMQXFA talks on Thursday

MQXFA Yield Assumptions and Actual

▪ All magnet fabrication steps are at peak production rate

▪ Yield assumptions based on LARP program:

14

* Including magnet assembly and vertical test

Cable Fabr.

& Insulat.

Coil

Fabrication

Total Coil

Yield*

Magnet

Vert. Test

Yield

assumption90% 87.5% 80%

Actual yield 92.2% 86.1% 83.5% 80%

% complete 74% 58% 25%

Fully assembled magnet

Coil after epoxy

impregnation


Schedule

▪ Working Schedule – August update:


Fermilab CoilsActivity Name Start Finish

Coil QXFA-138 Fab 20-Jul-21 A 14-Oct-21

Coil QXFA-139 Fab 06-Aug-21 A 9-Dec-21

Coil QXFA-140 Fab 16-Sep-21 24-Jan-22

Coil QXFA-141 Fab 12-Oct-21 17-Feb-22

Coil QXFA-142 Fab 5-Nov-21 15-Mar-22

Coil QXFA-143 Fab 3-Dec-21 8-Apr-22

Coil QXFA-144 Fab 4-Jan-22 4-May-22


Coil QXFA-146 Fab 24-Feb-22 24-Jun-22

Coil QXFA-147 Fab 22-Mar-22 21-Jul-22

Coil QXFA-148 Fab 15-Apr-22 16-Aug-22

Coil QXFA-149 Fab 11-May-22 12-Sep-22

Coil QXFA-150 Fab 7-Jun-22 6-Oct-22

Coil QXFA-151 Fab 1-Jul-22 1-Nov-22


Coil QXFA-153 Fab 23-Aug-22 27-Dec-22






Brookhaven CoilsActivity Name Start Finish

Coil QXFA-227 Fab 11-Jun-21 A 13-Oct-21

Coil QXFA-228 Fab 12-Jul-21 A 8-Nov-21

Coil QXFA-229 Fab 04-Aug-21 A 6-Dec-21

Coil QXFA-230 Fab 30-Aug-21 A 5-Jan-22

Coil QXFA-231 Fab 27-Sep-21 1-Feb-22

Coil QXFA-232 Fab 26-Oct-21 2-Mar-22





Coil QXFA-237 Fab 10-Mar-22 8-Jul-22



Coil QXFA-240 Fab 25-May-22 23-Sep-22

Coil QXFA-241 Fab 21-Jun-22 19-Oct-22


Coil QXFA-243 Fab 11-Aug-22 12-Dec-22



Coil QXFA-246 Fab 27-Oct-22 3-Mar-23





Activity Name Start Finish

Magnet Ass'y MQXFA-09 15-Jun-21 A 12-Oct-21

Magnet Ass'y MQXFA-10 8-Oct-21 15-Dec-21

Magnet Ass'y MQXFA-11 19-Nov-21 2-Feb-22

Magnet Ass'y MQXFA-12 10-Jan-22 16-Mar-22

Magnet Ass'y MQXFA-13 22-Feb-22 27-Apr-22

Magnet Ass'y MQXFA-14 5-Apr-22 9-Jun-22

Magnet Ass'y MQXFA-15 17-May-22 22-Jul-22

Magnet Ass'y MQXFA-16 29-Jun-22 2-Sep-22

Magnet Ass'y MQXFA-17 11-Aug-22 20-Oct-22

Magnet Ass'y MQXFA-18 23-Sep-22 13-Dec-22

Magnet Ass'y MQXFA-19 1-Dec-22 6-Mar-23

Magnet Ass'y MQXFA-20 27-Jan-23 25-Apr-23

Magnet Ass'y MQXFA-21 20-Mar-23 15-Jun-23

Magnet Ass'y MQXFA-22 5-Jun-23 31-Aug-23

Magnet Ass'y MQXFA-23 18-Jul-23 27-Sep-23

Magnet Ass'y MQXFA-R1 29-Aug-23 1-Nov-23

Magnet Ass'y MQXFA-R2 11-Oct-23 15-Dec-23

Magnet Ass'y MQXFA-R3 22-Nov-23 2-Feb-24

Magnet Ass'y MQXFA-R4 11-Jan-24 15-Mar-24

Conclusions

▪ The fabrication of MQXFA (HL-LHC low-beta quad)

magnets by US-AUP is at peak production rate

▪ Yields of magnets and sub-components are

consistent with AUP assumptions

▪ Additional conductor and coil parts are under

procurement in order to be able to fabricate

additional cables and coils if needed

▪ Last magnet to be completed around end of 2023


Back up Slides


Below the Surface…

G. Ambrosio - MQXFA Magnet Production in the US18

▪ Before MQXFA Pre-Series Magnets:

▪ Several Nb3Sn quadrupoles magnets with

bladder & Key structure by the LHC

Accelerator Research Program (LARP)

▪ One MQXF short coil and one long coil tested in “mirror

magnet” by LARP

▪ Five MQXFS short models, many re-assemblies and many

tests by LARP/CERN/AUP (S1a/b/c/d/e) and CERN

(S3a/b/c, S4a/b/c, S5, S6a/b/c)

▪ Two MQXFA prototypes and one re-assembly by

LARP/AUP

▪ One MQXFB prototype by CERN

Model Magnet Development Chart (by LARP)

19

Large aperture quadrupoles Long quadrupoles

HQ and LQ

Mirrors

HQM

Started from simple configurations directed at basic technology studies and

progressed to incorporate all requirements for operation in the accelerator

2003

2018

Coil design selection

Structure selectionLessons

Learned

MQXF design in

collaboration with CERNG. Ambrosio - MQXFA Magnet Production in the US

Low- quadrupole magnets

from LHC to HL-LHC

• Cold mass OD from 490/420 to 630 mm

• More than double the aperture: from 70 to 150 mm

• ~4 times the e.m. forces in straight section

• ~6 times the e.m. forces in the ends


20

MQXBMQXA

MQXF

Same scale for all 3 plots

State of the art quadrupoles at the time of LHC construction

MQXFA/B Design

PARAMETER Unit MQXFA/B

Coil aperture mm 150

Magnetic length m 4.2/7.15

N. of layers 2

N. of turns Inner-Outer layer 22-28

Operation temperature K 1.9

Nominal gradient T/m 132.2

Nominal current kA 16.23

Peak field at nom. current T 11.3

Stored energy at nom. curr. MJ/m 1.15

Diff. inductance mH/m 8.26

Strand diameter mm 0.85

Strand number 40

Cable width mm 18.15

Cable mid thickness mm 1.525

Keystone angle 0.4

21

P. Ferracin et al., “Development of MQXF, the Nb3Sn Low-β Quadrupole for the

HiLumi LHC ” IEEE Trans App. Supercond. Vol. 26, no. 4, 4000207

Nb3Sn Conductor

RRP 108/127

G. Ambrosio et al., “First Test Results of the 150 mm Aperture IR Quadrupole

Models for the High Luminosity LHC” NAPAC16, FERMILAB-CONF-16-440-TD


Documents

MQXFA Magnet Production in the US