1. May 9, 2012D. R. Dietderich, LARP CM-18 Cable Fabrication Plans and Experience D.R. Dietderich Lawrence Berkeley National Laboratory bnl - fnal- lbnl - slac US LHC Accelerator Research Program

2. May 9, 2012D. R. Dietderich, LARP CM-18 Outline of the Presentation Cable inventory for HQ/LHQ and plans Cable R&D – 140mm to 150mm bore –Cable fabrication of 217 stack R&D to reduce HQ cable dimensions –Wire diameters 0.778 mm and 0.80 mm Cored cable R&D

3. May 9, 2012D. R. Dietderich, LARP CM-18 HQ/LHQ Cable Parameters & Processing Nominal Parameters –Annealed wire 185-190C for 4 hours –Wire diameter: 0.778 mm –Thickness: 1.375 mm –Width: 14.8 mm –Keystone Angle – 0.75 deg. Stainless steel core, biased towards thick edge –Tape composition - 316L stainless steel –8 mm wide –0.025 mm thick

4. May 9, 2012D. R. Dietderich, LARP CM-18 HQ/LHQ Cable Status Cable available for coil winding –Z will denote a cable with a core. –1020Z-D 1UL insulated –1021Z – A1, A2, B (4 UL) 1 UL insulated braided on by NEW Insulation layer thickness 0.104 mm –Nearly the same thickness as prototype run with 0.103 mm. Used in HQ coil 17 3 UL insulated with sleeve from Rev. Comp. –1021Z-C – R&D 1UL NOT insulated, PL ~85 mm 1024Z – 5 UL fabricated, 1 UL 1 insulated 4 UL-HQ (400m) not insulated (Save for HQ for LHQ) Ti doped Used HQ coil 18 1025Z – 1 UL (300m) LHQ practice cable Ready to insulate at NEW

5. May 9, 2012D. R. Dietderich, LARP CM-18 Next LHQ/HQ Cable Run May to August –LHQ cable, fabricate 2 UL (May) Standard HQ/LHQ cable with core –HQ cable with RRP 217 stack, 1+ UL (June) Standard HQ/LHQ cable with core –MQXF Cable for140-150mm bore (July- August) R&D run to define cable parameters 40 strands Wire diameter ~0.85 mm

6. May 9, 2012D. R. Dietderich, LARP CM-18 Cable for 140-150 mm Bore

7. May 9, 2012D. R. Dietderich, LARP CM-18 Possible Cable Parameters for 140 mm If wire diameter is 0.85 mm the cable: Width:~18.25 mm Thickness: ~1.50 mm Keystone angle:~0.65 deg.

8. May 9, 2012D. R. Dietderich, LARP CM-18 Cored Cable 1012 Used in HQ Coil 12 HQ cable 1012 (old cable parameters) –35 strands with diameter of 0.80 mm –1.44 mm mid-thickness, Did not increase mid-thickness with core addition –15.1 mm wide –0.75 deg. Keystone angle –8 mm wide, 0.025 mm thick stainless steel core Biased to thick edge of cable –Core biased toward thick edge of the cable No fabrication issue with the addition of a SS core Addition of the core did not degrade the I c –Measurements show a reduction of ~3% which is typical for this cable without a core Mandrel with slot for adding a core

9. May 9, 2012D. R. Dietderich, LARP CM-18 Objective of Cable R&D To use existing HQ tooling cable dimensions needed to be reduced to: –Provide more space azimuthally (i.e. thinner cable) –Provide more radial space (i.e. narrower cable) Cable R&D targets dimensions: –Reduce HQ cable thickness by 65-100 microns To 1.375 mm - 1.340mm –Width target is < 15mm (14.7mm -15mm) Accommodates dimensional changes of cable during reaction Thicker insulation or more insulation between layers and tooling –Keystone angle un-changed at 0.75 deg.

10. May 9, 2012D. R. Dietderich, LARP CM-18 HQ Cable Parameters of R&D Cables TQLQ New HQ cable HQ Box Zone with Too much damage

11. May 9, 2012D. R. Dietderich, LARP CM-18 Critical Current Cable 1014 with 0.80 mm Un-deformed Round Wire Extracted Strands

12. May 9, 2012D. R. Dietderich, LARP CM-18 RRR 1014 – 0.80 mm wire Un-deformed Round Wire

13. May 9, 2012D. R. Dietderich, LARP CM-18 Critical Current Cable 1015 – 0.778 mm wire Un-deformed Round Wire Extracted strands 1 st Production cable 1017

14. May 9, 2012D. R. Dietderich, LARP CM-18 Cable 1015 Sections I & L No significant sub- element damage is observed in the wire cross-sectional images 1015-L 1015-I

15. May 9, 2012D. R. Dietderich, LARP CM-18 Summary HQ and LHQ cabling process established Target cable parameters for MQXF presented The critical current variation can be due to: –Sample handling while preparing for J c testing? –Or localized damage in some strands during cabling? – Suggests that a cable testing facility is needed for accurate cable critical current measurements. A stainless steel core can be added to the standard HQ cable without significant loss of critical current

16. May 9, 2012D. R. Dietderich, LARP CM-18 Extra slides

17. May 9, 2012D. R. Dietderich, LARP CM-18 1 Pass Cable with Stainless Steel Core

18. May 9, 2012D. R. Dietderich, LARP CM-18 LARP Cable Fabrication 2 pass process was developed to reduce dimensional changes of a cable during coil processing and reaction –A cable is fabricated oversize in thickness, annealed (200C for 2-4 hrs), and re-rolling to final thickness. Very important -- Cable is permitted to get wider during the second pass The anneal reduces the residual stress in the cable and the cable shortens by 0.20 – 0.25%. 1 pass process has been developed for adding stainless steel (SS) cores to cables –Strand is annealed (190C for 4 hrs) prior to cabling –Cable is made to final dimensions Due to the mechanical differences between the strand and the SS core a 2 pass process is not possible. However, other core materials such as S-glass tape or MgO paper tapre with a SS core

19. May 9, 2012D. R. Dietderich, LARP CM-18 Cable R&D to Reduce Cable Size The next slide shows the thickness and width of several cable samples –Cable 1014 34 strands with a diameter of 0.80 mm –Cable 1015 35 strands with a diameter of 0.778 mm Blue Box denotes the target parameters needed to accommodate the cable dimensional changes in the present tooling. –Dash line are the deduced parameters from R&D on TQ and LQ coils Red Circle denotes the new HQ parameters with the 0.778 mm diameter strand

20. May 9, 2012D. R. Dietderich, LARP CM-18 R&D to Reduce HQ Cable Dimensions New cable parameters: –Mid-thickness 1.375 mmfrom 1.44 mm –Width14.80 mmfrom 15.10 mm –Keystone angle0.75 deg.Unchanged New cable designs will provide more space in tool for cable dimensional changes –Have made the first production cable 1017 with new parameters HQ coil 14 has been fabricated and is ready to test in a mirror. –Have just made a cored cable with the new cable parameters with a strand diameter of 0.778mm. Coil winding with the cored cable was OK –However, popped strands were produced going around the pole They are pushed back into position as winding continues –Planning to cut HQ coil 12 into sections for inspection.