1. Dan Cheng 8/27/2015 MQXFS1 Observations and Feedback from the Assembly Processes, Part II

2. Outline 8/27/2015 MQXFS1 Assembly Observations and Feedback Part II 2 Observations and feedback on assembly processes (old) Axial end loading modifications (new) Summary and Status (updated)

3. Improved Coil Support Spud 8/27/2015 MQXFS1 Assembly Observations and Feedback Part II 3 Procedures and tooling were adjusted after the disassembly incident Redesigned coil support spud was incorporated into the use of coil pack builds #3-5 – Screws positively engage with each coil to prevent relative motion

4. MQXFS1 Coil Pack Insertion Rails 8/27/2015 MQXFS1 Assembly Observations and Feedback Part II 4 Coil pack was inserted into the shell & yoke assembly with the insertion rails

5. MQXFS1 Coil Pack Insertion Rails 8/27/2015 MQXFS1 Assembly Observations and Feedback Part II 5 Rails were removed when the bladders were first cycled

6. MQXFS1 Master Keys & Shims 8/27/2015 MQXFS1 Assembly Observations and Feedback Part II 6 MQXFSD Alignment and load keys required many shims in nominal dimensions MQXFS1 keys were increased in thickness – 1 mm per each load key half, and 2 mm in alignment key – This reduced the amount of shim required during bladder operations Material was changed to bronze instead of mild steel

7. MQXFS1 Wire Routing 8/27/2015 MQXFS1 Assembly Observations and Feedback Part II 7 IL wiring is being routed under the axial end plates via SLA (Accura Bluestone) wire guides

8. Threaded holes in Collars 8/27/2015 MQXFS1 Assembly Observations and Feedback Part II 8 There are still some chips that are being generated by the screwing/unscrewing process of the aluminum collarpacks – Chips were vacuumed after bolting operations Long magnet designs plan for Load Pad and Collar stacks to be preassembled, and only load pads would be bolted – CERN has already tested this option in the short model with promising results

9. Feedback on Axial Loading 8/27/2015 MQXFS1 Assembly Observations and Feedback Part II 9 First time the axial loading rig was used with real coils (with leads) – Copper-stabilized leads made it difficult to position aluminum pusher w/o damaging Kapton around cable – Size of pressure cylinder required hardway bending of exiting leads due to the sizes of the aluminum pusher, cylinder mounting baseplate, and backing plate

10. Feedback on Axial Loading 8/27/2015 MQXFS1 Assembly Observations and Feedback Part II 10 Modifications employed – Changed pressure cylinder from RSM-1000 to RSM-750 Loading only required 18,000 lbs. force (4000 psi on 4.5 in 2 ) – Cylinder change reduced radial requirement by ¼” (6.35 mm) = less hardway bend Cut back surfaces on aluminum pusher, cylinder mounting base, and backing plate – Also added a generous radius (¼”) to the pusher channels (next slide)

11. Feedback on Axial Loading 8/27/2015 MQXFS1 Assembly Observations and Feedback Part II 11 Temporary protection of leads using sections of heat-shrink tubing Radii on edge of grooves

12. Summary 8/27/2015 MQXFS1 Assembly Observations and Feedback Part II 12 Magnet assembly incorporated improvements – Redesigned coil support spud was used – Coil pack insertion rails were used successfully – Increased key thicknesses to reduce required shimming – Wire guides to protect and route instrumentation wires – Axial loading system required some modifications Status – Axial loading was completed this week – Electrical QA result show no issues (report to follow) – Pizza box is being fabricated; magnet splice activities to start next week – Connector mounts & wiring and magnet support are in fabrication – Shipping and handling is being coordinated between FNAL and LBNL

13. 8/27/2015 MQXFS1 Assembly Observations and Feedback Part II 13 Additional Slides