S. Caspi, LBNL

HQ Progress and Schedule

Shlomo Caspi

LBNL

LARP Collaboration Meeting – CM13 Port Jefferson

November 4-6, 2009

S. Caspi, LBNL

• The LARP ProgramThe LARP Program

• HQ design highlightsHQ design highlights

• Coil fabricationCoil fabrication

• Magnet statusMagnet status

• SummarySummary

OutlineOutline

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S. Caspi, LBNL

LARP - Magnet R&D Program

1. Nb3Sn Technology - TQ

• Conductor studies• Coil fabrication• Mechanical support• Modeling tools• Quench protection

2. Length scale-up - LQ

• Coil technology • Quench protection

3. Design optimization - HQ

• Larger aperture• higher energy and forces• Accelerator quality

LARP CM 13, Port-Jefferson November 4-6, 2009 3

S. Caspi, LBNL

Completed HQ tasks

LARP CM 13, Port-Jefferson November 4-6, 2009

• Magnetic design:• field quality, conductor field

• Mechanical design:• Tooling :

• Winding• Curing• Reaction• Impregnation

• Cable:• Size• Winding

• Alignment and assembly• Ground plane insulation• Traces – voltage taps and protection heaters• Pre-stress, cool-down, power

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HQ Collaboration

• LBNL - Mechanical design, coil winding, curing, reaction, instrumentation, impregnation and magnet assembly.

• BNL - Coil reaction, instrumentation, and impregnation.

• FNAL – Magnetic design, end spacers design and fabrication.

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Design Concept and Guidelines

• CCoil alignmentoil alignment– Collars and keys for azimuthal alignment (Collars and keys for azimuthal alignment (not for pre-stressnot for pre-stress))– Maintain full azimuthal contact between coil-island and collar– Bladder and key locations to balance layers pre-stress

• Shell based Aluminum structure - Shell based Aluminum structure - final pre-stress during cool-down

LARP CM 13, Port-Jefferson November 4-6, 2009

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S. Caspi, LBNL

Coil aperture mm 120Overall magnet diameter mm 570Jc 12T, 4.2 K, RRP 108/127 A/mm2 3000Maximum gradient 4.4 K/1.9 K T/m 199/219Maximum current 4.4 K/1.9 K kA 17.7/19.5Peak field 4.4 K/1.9 K T 13.9/15.2Max. stored energy 1.9 K MJ/m 1.4Max Fθ forces 1.9 K, IL/OL MN/m -1.92/-3.2Maximum axial force per end MN 1.4

HQ Parameters

LARP CM 13, Port-Jefferson November 4-6, 2009 7

S. Caspi, LBNL

HQ Model - ANSYS 3D Analysis

1. Axial pre-load

2. Azimuthal pre-load

3. Cool-down

4. Excitation

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S. Caspi, LBNL

HQ - Average Azimuthal Stress

Location (MPa)Assembly

(MPa)Cool-down

(MPa)220 T/m

Layer 1 pole-turn -48 -140 -7

Average stress in HQ is 140 MPa but local stress expected to exceeds 200 MPa

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S. Caspi, LBNL

R of 78 m

* Large scale factor to simulate displacements

Field Quality - With Lorentz forces at 219 T/m

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S. Caspi, LBNL

Protection

Protection Parameters (Quench Pro):

-Detection time = 5 ms

-Heater delay time Layer 1: heat diffusion: 15 msLayer 2: heat diffusion + propagation = 20 ms

- Coverage = 60 %- Quench propagation velocity = 10 m/s- Dump R = 50 mohm

Hot spot temperature:

- 4.2 K short sample: 322 K

-1.9 K short sample: 400 K

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Coil Preparation and Fabrication

Wire EDMRapid Prototyping (RP)CAD

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S. Caspi, LBNL

Winding and Curing

Coil Winding Curing

Cured Layer 1

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S. Caspi, LBNL

Reaction and Impregnation

•72 hr at 210 C

•48 hr at 400 C

•48 hr at 665 C

Reaction Tooling

Impregnation ToolingPost Reaction: NbTi Leads, VT, SG.

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Impregnated Coil (PC1)

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S. Caspi, LBNL

HQ Coil Status

LARP CM 13, Port-Jefferson November 4-6, 2009

Unit Length (one coil layers 1 & 2, 81m net ) – Add 19m of lead = 100m or 16Kg/UL16Kg/UL

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HQ Coil Status

• Practice coils 1 and 2 completed, PC1 instrumented ready for mirror test.

• Coil 3 - start reaction November 9 (LBNL)

3 – Impregnation complete December 11 (LBNL)

• Coil 4- ready for reaction (BNL)

4 - Impregnation complete December 23 (BNL)

• Coil 5 – Wind and cure complete November 16 (LBNL)

5 – start reaction Dec 7 2009 (LBNL)

5 – Impregnation complete January 30 2010 (LBNL)

• Coil 6 – Wind and cure complete December 23 (LBNL)

6 – Start reaction January 8 2010 (BNL)

6 – Impregnation complete February 14 2010 (BNL)

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HQ Structure, Assembly, Test - Status

• Collars assembly completed (LBNL).

• Pads assembly November 30 (LBNL).

• Yoke assembly November 30 (LBNL).

• Shell-Yoke subassembly Dec 15 (LBNL).

• HQ cool-down test (dummy coils) January 2010 (LBNL)..

• HQ01a final assembly March 1 2010 (LBNL)..

• HQ01a test March 15 2010 (FNAL).

S. Caspi, LBNL

HQ Summary

• A 120 mm bore, Nb3Sn quadrupole for Phase II is under construction

• With a current density conductor of 3000 A/mm2 (12 T, 4.2 K) the magnet is expected to reach 15 T at 1.9 K (219 T/m)

• The magnet is optimized for alignment and field quality

• Assembly and pre-stressed with an outer Aluminum shell and “key and bladder” technology.

• Final assembly and testing Q2 2010.

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