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
LARP CM 13, Port-Jefferson November 4-6, 2009 2
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
4
S. Caspi, LBNL
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.
LARP CM 13, Port-Jefferson November 4-6, 2009 5
S. Caspi, LBNL
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
6
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
LARP CM 13, Port-Jefferson November 4-6, 2009 8
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
LARP CM 13, Port-Jefferson November 4-6, 2009 9
S. Caspi, LBNL
R of 78 m
* Large scale factor to simulate displacements
Field Quality - With Lorentz forces at 219 T/m
LARP CM 13, Port-Jefferson November 4-6, 2009 10
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
11
S. Caspi, LBNL
Coil Preparation and Fabrication
Wire EDMRapid Prototyping (RP)CAD
LARP CM 13, Port-Jefferson November 4-6, 2009 12
S. Caspi, LBNL
Winding and Curing
Coil Winding Curing
Cured Layer 1
LARP CM 13, Port-Jefferson November 4-6, 2009 13
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.
LARP CM 13, Port-Jefferson November 4-6, 2009 14
S. Caspi, LBNL
Impregnated Coil (PC1)
LARP CM 13, Port-Jefferson November 4-6, 2009 15
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
16
S. Caspi, LBNL 17
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)
S. Caspi, LBNL 18
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.
LARP CM 13, Port-Jefferson November 4-6, 2009 19