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LARP magnet R&D program
Giorgio AmbrosioTD/MSD
FNAL Annual Program ReviewSeptember 07
OUTLINE
• LARP goals• FNAL contribution to LARP• FNAL core-program support to LARP
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G. Ambrosio - LARP magnet R&D program
LARP goals “ The US LHC Accelerator Research Program enables U.S.
accelerator specialists to take an active and important role in the LHC accelerator during its commissioning and operations, (…) and to be a major collaborator in LHC performance upgrades” (mission statement)
Form FY08 Org Chart
LARP magnet R&D (FNAL, BNL, LBNL)• From start to FY07: focus on R&D• From FY08: focus on “projectized” tasks
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LARP 2009 Milestone
LARP has a very challenging milestone at the end of 2009
“Demonstrate that Nb3Sn magnets are a viable choice for an LHC IR upgrade”
Technological Quadrupoles (TQ) for performance reproducibility
1 m long, 90 mm aperture, Gnom > 200 T/m, Bcoil > 12 T
Long Racetracks and quadrupoles (LQ) addressing long magnet issues
LQs have same features of TQs 4 m long
High gradient quadrupoles (HQ) to explore performance limits
1 m long, 90+ mm aperture, Gnom > 250 T/m, Bcoil > 15 T
Milestone set in agreement with CERN
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FNAL contribution
“Demonstrate that Nb3Sn magnets are a viable choice for an LHC IR upgrade”
Technological Quadrupoles (TQ) for performance reproducibility
1 m long, 90 mm aperture, Gnom > 200 T/m, Bcoil > 12 T
Long Racetracks and quadrupoles (LQ) addressing long magnet issues
LQs have same features of TQs 4 m long
High gradient quadrupoles (HQ) to explore performance limits
1 m long, 90+ mm aperture, Gnom > 250 T/m, Bcoil > 15 T
FNAL: Host lab for TQC magnets
FNAL: TQS coil winding & curingTQS magnet test at 1.9K
FNAL: L2 coordination
FNAL: Design Study L2 coordination
FNAL: LQ coil development and fabrication, LQ design with alignment, LQ test at 1.9KFNAL: Design
Study task leader
FNAL: Contribution to all WGsStrand study task leaderMagnet test coordination leaderOnly lab for 1.9K magnet test
Long Mirror (LM) addressing long coil & magnet issues
2 and 4 m long, single cos coil, Bcoil ~ 11 T
FNAL core program taskIn support of LARP
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Technological Quadrupoles Two mechanical designs are under developmentSame coils / Aperture = 90 mm / Gradient > 200 T/m @ 4.2K
2 layers
FillerKeys
4 pads
Bladder
Yoke
Aluminum shell
TQC: using collarsCollar laminations from LHC-IR quads1st time applied to Nb3Sn coils
TQS: using Al-shellPre-loaded by bladders and keys1st time applied to shell-type coils
YokeGap
Collar-YokePreloadShim
ControlSpacer
Skin
Collar
YokeCollaringKey
Inner poleOuter polepiece
Coil MidplaneShim
FNAL: concept, design, development, coils fabric., assembly & test
FNAL: coils fabric, test at 1.9K
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TQ Coil Fabrication
• TQ coil fabrication techn. is mostly based on FNAL technology
Water Jet Machined Part
Ceramic binder for insulation, water-jet technology for end-parts, reaction procedure with azimuthal and pole gaps, segmented tooling with “gentle-transfer” procedure, splice design and procedure
• All coils (29) for the 1st magnet series have been wound and cured at FNAL, reacted and impregnated at LBNL;
• TQC02 coils completely fabr. at FNAL
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TQC Development
• New FEM analysis with Nb3Sn plasticity (1st in the field)
• Four mechanical models have been assembled and tested in order to develop collaring procedure for Nb3Sn coils
Stress in different longitudinal sections during keys insertion: uniform within +/- 5 MPa
0
10
20
30
40
50
60
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100
0 0.001 0.002 0.003 0.004 0.005 0.006
Strain
Str
ess,
MP
a
Elasticity
GPa
Plasticity
free
5 m
m (
blo
ck 1
)
5 m
m (
blo
ck 2
)
5 m
m (
blo
ck 3
)
5 m
m (
blo
ck 4
)
7 m
m (
blo
ck 1
)
7 m
m (
blo
ck 2
)
7 m
m (
blo
ck 3
)
7 m
m (
blo
ck 4
)
9 m
m (
blo
ck 1
)
9 m
m (
blo
ck 2
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9 m
m (
blo
ck 3
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9 m
m (
blo
ck 4
)
9.3
mm
all
blo
cks
-80
-70
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-40
-30
-20
-10
0
Key travel
Stress strain plot showing plastic-elastic behavior of coil samples
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TQCs Status and Plans
TQC01:– 70% at 4.5K– 85% at 1.9K – Damage during test
TQC01b:Re-assembly with 2 TQS
coils– 85% ssl at 4.5 K– 89% at 1.9 K– Reached G = 200 T/m
Constant improvement in understanding and process control
TQE02:TQC with TQS02 coils– To be tested early Oct
TQC01b training history
TQS02 (with RRP 54/61 coils) assembled at LBNL, tested at FNAL, reached ~215 T/m at 4.5 K
TQC01b Quench Training at 4.5K and 1.9K
50006000700080009000
10000110001200013000
0 20 40 60 80
Quench #
Cu
rre
nt (A
)Coil 07
Coil 08
Coil 10
Coil 12
4.5K 1.9K
13400 A
12400 A4.5K
TQC01b Quench Training at 4.5K and 1.9K
50006000700080009000
10000110001200013000
0 20 40 60 80
Quench #
Cu
rre
nt (A
)Coil 07
Coil 08
Coil 10
Coil 12
4.5K 1.9K
13400 A
12400 A4.5K
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Plan for Length Scale-Up
LENGTH SCALE-UP CHALLENGE: No Nb3Sn accelerator magnet longer than 1m has ever been builtLARP should make a successful 4m long quadrupole by end of 09
FNAL Long MirrorsFNAL
LARP Long QuadrupolesFNAL, LBNL, BNL
LARP LQ Design Study
LARP Long RacetracksBNL, LBNL, FNAL
2006
2007
2008
2009
LARP TQs
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LARP Long Racetrack
The goals of the Long Racetrack (LR) are: to fabricate and test long Nb3Sn racetrack coils Performed at BNLto test an Al-shell-based supporting structure Developed at
LBNL(preloaded using bladders and keys)
FNAL contributions:L2 coordination of Supporting R&D (G. Ambrosio)FNAL scientists and engineers are part of LR working groupTechnology transfer from the LR to the LQ, Insulation development, Practice coil insulation
Coil layout: two flat double-layer racetrack coilsTechnology developed at LBNL, modified at FNAL, successfully transferred to BNL
From 0.3 m to 3.6 m
Results:
- Iq> 90% ssl
- Shell should ..be segmented
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FNAL Long Mirror• FNAL “Mirror magnet” is a cos-theta dipole where a coil is
substituted by iron blocks• Successful 2m mirror magnet (same performance of 1m model)• 4m mirror magnet will be tested in November
Front view of mirror magnet
ADVANTAGES - Larger probability of success of the LQ by:Several features complementary to LRs Diversity & Risk mitigation
- conductor, keystoned cable, insulation, coil shape, use of wedges, mechanical structure,Start as soon as possible development and qualification of tooling and infrastructure for long magnets at FNAL (New 6-m long oven, …)
LM02 quenchhistory at 4.5Kcompared with 1m model
15000
16000
17000
18000
19000
20000
21000
22000
0 5 10 15 20 25 30
Quench number
Qu
ench
cu
rren
t, A
LM01
HFDM03
SSL
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LQ plans
Present plan (still under development):• LQ project leadership – FNAL• LQ coil winding & curing – FNAL• LQ coil reaction & impregnation – FNAL &
BNL• LQ support structure with shell – LBNL & BNL• LQ support structure with coil alignment –
FNAL• LQ quench protection – FNAL & LBNL & BNL• LQ magnet tests – FNAL & BNL
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Other parts of LARP magnet R&D
• FNAL has a major role in Design Studies: – LARP L2 coordinator (Zlobin) – LARP Long Quadrupole DS task leader (Ambrosio)– Tasks: High Grad Quad, IR Study, Radiation deposition,
Cryogenics, Heat transfer
• … also in Material R&D:– Strand R&D task leader (Barzi)– Tests of strands and cables in
different conditions (pressure, field, temperatures)
• … also in Magnet testing:– LARP magnet integration
coordination– Only LARP lab with 1.9K capability– Developed low-noise high-
frequency spike detection system
Tests of SQ02 (small quadrupole with racetrack coils) fabricated at LBNL
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Budget and Resources
FY07 resources: 5 physicists 8 engineers 2 designers 9 technicians + support. staff (~21 FTEs)
• The LARP budget is almost constant (+10%)• In FY08 the Core Program budget is decreasing because the Long Mirror is
phasing down ( low M&S, lower SWF); some FTEs to other magnet programs • In FY09 the Core Program budget is back to $4.6M in preparation for IRUP
• The continuity of the core program allows for continued growth in expertise and infrastructure we are able to respond quickly to the needs of the field
FY06 FY07 FY08 FY09
LARP magnet R&D
$1.9M
$1.9M
$2.0M
$2.1M
FNAL magnet R&D
$4.7M
$4.7M
$3.6M
$4.6M
Budget with G&A
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Conclusions
• LARP is starting an exciting and challenging phase– Goal: demonstrate that Nb3Sn magnets are viable
option for an LHC IR upgrade
• FNAL is supporting all LARP goals – With key contributions in all tasks
• technical and managerial level
– With unique contributions in several tasks• such as 1.9K magnet test capability, long coil winding
and curing, coil collaring, conductor characterization, …
– Has achieved important results (TQC01b)
• FNAL is providing further support by core-program – Long Mirror magnets, Conductor R&D
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LARP Mission Statement
The US LHC Accelerator Research Program enables U.S. accelerator specialists to take an active and important role in the LHC accelerator during its commissioning and operations, and to be a major collaborator in LHC performance upgrades. In particular, LARP will support U.S. institutions in LHC commissioning activities and accelerator science, accelerator instrumentation and diagnostics, and superconducting magnet R&D to help bring the LHC on and up to luminosity quickly, to help establish robust operation, and to improve and upgrade LHC performance. Furthermore, the work we do will be at the technological frontier and will thereby improve the capabilities of the U.S. accelerator community in accelerator science and technology to more effectively operate our domestic accelerators and to position the U.S. to be able to lead in the development of the next generation of high-energy colliders.
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LARP FY07 Org Chart
FY07 Org Chart
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LARP FY08 Org Chart
FY08 Org Chart
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SC Magnet R&D at Fermilab
• Fermilab has a long (~30 years) and successful history of SC accelerator magnet R&D– Tevatron, Low Beta Quads, SSC dipoles, VLHC superferric
transmission-line, LHC IR Quads, HFM dipoles
• This is because SC magnets are an enabling technology for high energy accelerators
“The tremendous accomplishments of these last two years confirm the broad strength of the group”
“In many areas basic elements of the Fermilab program, such as tests of material, establishment of fabrication processes, design and fabrication of tooling and fixtures, are essential to LARP success”
Jan 06 - High Field Magnet review (L. Rossi, chair)