1. Cold Mass and Assembly Tooling Design, Procurement Status and Assembly Plan Igor Novitski Fermilab 15 T Dipole Design Review 28-29 April 2016 April 28-29, 2016, FNAL Igor Novitski | 15T Dipole Design Review1

2. April 28-29, 2016, FNALIgor Novitski | 15T Dipole Design Review2 1.Cold mass design description 2.Drawing tree 3.Magnet assembly steps and tooling 4.Procurement status 5.Assembly tooling status 6.Conclusions Outline

3. Cold Mass Design Description April 28-29, 2016, FNALIgor Novitski | 15T Dipole Design Review3 1 – 4-layer Nb 3 Sn coil 2 –coil-yoke stainless steel spacer 3 – iron yoke laminations 4 – alignment key 5 – aluminum I-clamp 6 – iron filler 7 – stainless steel welded skin 8 – stainless steel axial rod 9 – stainless steel pusher plate 10 – bullet 11 – stainless steel end plate 12 – stainless steel ring 2 4 1 7 12 9 10 11 8 3 6 5

4. Drawing Tree April 28-29, 2016, FNALIgor Novitski | 15T Dipole Design Review4 CoilsTooling Cold MassTooling Coil assembly fixture Welding fixture Clamping fixture Lifting fixture

5. Magnet Assembly Steps Coil instrumentation Coil block assembly, PH and ground insulation placement Yoking Clamping Skin welding Ends loading Leads splicing Final electrical check April 28-29, 2016, FNALIgor Novitski | 15T Dipole Design Review5

6. Coil Instrumentation April 28-29, 2016, FNALIgor Novitski | 15T Dipole Design Review6 Strain gauges, VTs and Heaters

7. Coil Assembly April 28-29, 2016, FNALIgor Novitski | 15T Dipole Design Review7 Coil alignment pin LE RE

8. Coil Ground Insulation and Heaters April 28-29, 2016, FNALIgor Novitski | 15T Dipole Design Review8 PH design: SS strips 0.025x25mm (LF) and 0.025x32mm (HF) PH position: L4 and in between L2 and 3 PH insulation: single layer 127  m thick Kapton Coil weight=189.4 kg

9. Coil-Yoke Stainless Steel Spacer April 28-29, 2016, FNALIgor Novitski | 15T Dipole Design Review9 Two 2mm thick stainless steel shells

10. Coil Block Yoking Igor Novitski | 15T Dipole Design Review10April 28-29, 2016, FNAL Coil block rotated by 90 o Iron laminations with alignment keys lam weight=14.8 kg

11. Coil Block Yoking Igor Novitski | 15T Dipole Design Review11April 28-29, 2016, FNAL Axial tie rods

12. Yoke Clamping Igor Novitski | 15T Dipole Design Review12April 28-29, 2016, FNAL Tooling (in design stage) will push all clamp in final position gradually (travel ~5mm) Clamp weight=2.6 kg

13. After Yoke Clamping Igor Novitski | 15T Dipole Design Review13April 28-29, 2016, FNAL Weight=1546 kg

14. Shell Welding Preparation Lifting fixtures Igor Novitski | 15T Dipole Design Review14April 28-29, 2016, FNAL Work on a fixture certification in progress Several Iron lams will be modified

15. Shell Welding Preparation Igor Novitski | 15T Dipole Design Review15April 28-29, 2016, FNAL Stainless steel rings

16. Shell Welding Preparation Igor Novitski | 15T Dipole Design Review16April 28-29, 2016, FNAL Iron filler and backing strip

17. Shell Welding Igor Novitski | 15T Dipole Design Review17April 28-29, 2016, FNAL Tooling (in design stage) with welded rods (as in 11T). Hand welded shells

18. After Shell Welding Igor Novitski | 15T Dipole Design Review18April 28-29, 2016, FNAL

19. End Loading Preparation Igor Novitski | 15T Dipole Design Review19April 28-29, 2016, FNAL Pusher plate

20. End Loading Preparation Igor Novitski | 15T Dipole Design Review20April 28-29, 2016, FNAL Pusher plate

21. End Loading Igor Novitski | 15T Dipole Design Review21April 28-29, 2016, FNAL Return End plate

22. End Loading Igor Novitski | 15T Dipole Design Review22April 28-29, 2016, FNAL LE end plate

23. Leads Insulation Igor Novitski | 15T Dipole Design Review23April 28-29, 2016, FNAL Lead insulating spacers

24. Leads Splicing Igor Novitski | 15T Dipole Design Review24April 28-29, 2016, FNAL Stand-off plate

25. Leads Splicing Igor Novitski | 15T Dipole Design Review25April 28-29, 2016, FNAL G10 splicing plates

26. Leads Splicing Igor Novitski | 15T Dipole Design Review26April 28-29, 2016, FNAL G10 cover plate

27. Magnet Final Design Igor Novitski | 15T Dipole Design Review27April 28-29, 2016, FNAL 1100mm 612mm Weight=2362 kg

28. Procurement Status Igor Novitski | 15T Dipole Design Review28April 28-29, 2016, FNAL 2 4 1 7 12 9 10 11 8 3 6 5 Status: in house; in procurement; in production; in design.

29. Assembly Tooling Status Coil assembly station – need several (12) new spacers Iron yoke clamping – in design stage Iron yoke lifting – under certification Skin welding - in design stage Igor Novitski | 15T Dipole Design Review29April 28-29, 2016, FNAL

30. Conclusions A cold mass design is complete All cold mass parts are in procurement Design work is in progress for clamping and welding tooling and will be ready for the model assembly April 28-29, 2016, FNAL Igor Novitski | 15T Dipole Design Review30