1. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 LCLS Cavity BPM Production Status

2. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 M1-Tool Works BPM Production M1 awarded contract for machining bodies and transitions for 20 sets of parts First Production BPM mechanical measured and Pre-lim cold test look very good

3. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 First production unit

4. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Cavity Production Status M1-Tool Works to deliver 11 units 1/22/08 presently on schedule Exercised the option for additional 20 units order from M1-Tool 1/08 Parts are on time and in spec so far

5. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Cold Test Set-Up for Pre-Braze test New production test fixtures for pre-braze testing First production unit looks good and parts are at Altair waiting to be brazed

6. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Cavity BPM Cold Test Data Serial #Dipole Freq. (GHz) Dipole Loaded Q Monopole Freq. (GHz) Monopole Loaded Q Design Goal11.384355011.3843695 Production # 010 11.384 Pre-Braze 2987 Pre-Braze 11.379 Pre-Braze 2000 Pre-Braze Prototype # 001 11.374325011.3823372 Prototype # 002 11.376350011.3833436 Prototype # 003 11.377337111.4003200

7. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 First Production Unit Shipped to Serial # 010 shipped to Altair for brazing 12/21/07 Unit pending complete braze due to window problem

8. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Production Risks (Presented at FAC 10/30/07) New End Cap design New tuning scheme Window plating problem Unexpected integration problem Unexpected vendor problem

9. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 The Window Braze Yield Problem Problem brazing the window into the transition has caused delivery delay Convergence and down-select of possible solutions pending Concentration of effort critical

10. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Understanding the Problem History  Why were ALL the soldered units vacuum tight? 15 for 15  Why did the units built for the 3-BPM work so well compared to present results 6 small leaks, 9 good NO CRACKING

11. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 BPM Window Braze History Prototype cold test unit, ITS test unit and 3-BPM test unit S/N 01 soldered Sn-Ag-Cu Vacuum tight 2 test brazes Georo Vacuum tight 3-BPM S/N R/0 first Georo braze Vacuum tight

12. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Georo Test Braze before 3-BPM units First test brazes clean and vacuum tight 5/12/07 No risk at this time so units for 3-BPM testing would be processed with Georo braze material

13. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 First Problem Window 3-BPM test Ser # 03 Georo Braze Results:  2 out of 5 leaked and the 2 that leaked had “glossy” Ni plating 3-BPM test Ser # 02 Georo Braze Results:  4 out of 5 leaked and the 4 that leaked had “glossy” Ni plating

14. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Corrective Action from 3-BPM Window Failures Start R&D program to identify problem with bright Ni CPI suggested using gold plating of first trials First sample failed 10/07 because of apparent cracks and “spattering” Possible cause was cool down too rapid

15. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Window Problem Status 01/21/08 Moly retaining ring and retaining outer block Lower temperature braze (Orotin) with induction heating re-work CPI supplies transition with window installed Kovar frame Two piece transition Bolt on window Coax adapter

16. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Cavity BPM Production Recovery Options without changing the design Option 1 Lower temperature braze (Orotin) and Induction heating re-work plan Option 2 Work with CPI for a turn-key solution providing completed transition Option 3 Braze window into a frame (Kovar) with similar expansion coef and weld into transition

17. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Braze with existing/modified parts  PROs Lowest risk option Fastest recovery Re-work plan possible Lowest cost impact No risk to qualified BPM system design  CONs Yield not satisfactory Re-work plan needs work

18. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Induction Heating Working with Ameritherm to re-work window after failed braze Braze can be re-worked by applying additional paste or powder to joint

19. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Receiver Electronics Production Status All parts on order Test fixtures developed Parts to start arriving 2/08

20. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Production Status M1-tool Works delivered first unit 11/07 on time and in spec First unit has been QA tested and cold tested with very good results First unit is at Altair being Brazed less waveguide transitions ANL to supply Altair with first set of modified window/transitions Addition 11 BPMs in process at ANL

21. Bob Lill LCLS week meetingBlill@aps.anl.gov January 22-24, 2008 Production Milestones Production of 1 BPMs for LTU 02/08 Production of 11 BPMs for undulator/LTU 03/08 Production of 12 BPMs for undulator 04/08 Production of 12 BPMs for undulator 05/08 Spares 4 BPMs 06/08 40 sets of Electronics 08/08