1. ATF2 quads status 22Nov05- Cherrill Spencer 1 Status Report on the Design and Fabrication of 29 quads for ATF2 By Cherrill Spencer, SLAC, for ILC-BDS weekly meeting on 22 nd November 2005

2. ATF2 quads status 22Nov05- Cherrill Spencer 2 ATF2 quadrupoles : QEA-D32T180 Activity from June – September 2005 Are 8 quadrupoles in the extension of the ATF extraction line Are 6 quads in matching section of ATF2 beamline Are 14 quads in final focus section of ATF2 ( aside from QF1&QD0) Decided back in June these 3 sets could all be made from same design. Decided an existing KEK quad called the TOKIN 3390 (“QB4” style) would be basis of the design for the 28 ATF2 quads listed above. Contract signed in early July with the Magnet Shop of the Institute of High Energy Physics (IHEP) in Beijing, China to make new drawings and fabricate 29 quads (1 spare) by March 31 st 2006. In July: Spencer wrote very detailed specifications for this quad, new name: QEA- D32T180. Defined precisely the type of materials to be used, the fabrication processes to be followed and the tolerances to be met. Used USA and Japanese standards. Sent some top assembly drawings of TOKIN 3390 to IHEP. August-September: IHEP drew new drawings for all parts and assemblies. IHEP and Spencer negotiated substitute Chinese materials to be used where Spencer could qualify them to her satisfaction.

3. ATF2 quads status 22Nov05- Cherrill Spencer 3 ATF2 quadrupoles : QEA-D32T180 Activity from September- December 2005 Late September: new drawing package released by IHEP for review. Formal review held by marathon video-conference on 29/ 30th Sept. See examples of new drawings (not yet final) on next slides. October-November : Spencer continues negotiating changes in fabrication processes and materials to accommodate capabilities of IHEP magnet shop and availability of materials, so tight schedule can be met. Mid-Late October: IHEP designing and fabricating coil winding forms October-Late November: IHEP machining first magnet’s 4 steel core pieces Late November: hollow copper conductor due to arrive from Finland Early December: Wind and pot first 4 coils Early Dec.: finish machining 1 st magnet’s poletips with Electric Discharge Machine December 8 th – 14 th Spencer will visit Magnet Shops at IHEP to observe coil winding, potting, core assembly and first magnet’s full assembly. Core will be measured with CMM and other QC tools to check tight tolerances are met. Coils will be tested. December onwards: if 1 st magnet passes all tests Spencer will allow rest of magnets to be fabricated. Magnetic measurements will start in mid-January.

4. ATF2 quads status 22Nov05- Cherrill Spencer4 3 ). Detail of coil 3. Coil manufacturing NOT FINAL COIL DRAWING: DO NOT USE

5. ATF2 quads status 22Nov05- Cherrill Spencer5 1). Overview of general assembly: QEA-D32T180. 4. General Assembly NOT FINAL DRAWING. DO NOT USE 32mm bore 180mm core length 47 turns per water cooled coil Max gradient 55 T/m

6. ATF2 quads status 22Nov05- Cherrill Spencer6 5. Flow Chart for Manufacture Inspection/measure Manufacture Special procedure Core Cutting Magnetization Anneal Painting Core machining Core Assembling Appearance inspection Size inspection Electric connection Coils assembling Gap inspection Water pressure test Assembly electric test Magnetic measurement Drain water by blow N2 Label and mark polarity and package Delivery/Shipment Outside lead insulation Welding for conductors and water connector blocks and thermal interlock mounting blocks. Conductor cleaning Pre-winding insulation Winding Ground insulation Size inspection Electric measure Impregnation Size inspection& Electric measure Lead Bending Ball test for water route Cleaning Leakage test Coil