1. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage From Physics model to Engineering model

2. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage SNS JPARC MOD_JPARC TRASCO THIN Vane type RFQ designs Spallation Neutron Source Japan Proton Accelerator Research Complex Trasmutazione Scorie

3. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage SNS:Spallation Neutron Source Where:Lawrence Berkeley National Lab (LBNL) RFQ type:4 vane Beam type:H- Beam Acceleration:65 keV to 2.5 MeV Operating frequency:402.5 MHz Beam current:52 mA Length:4 x 3.7 metre sections Cooling channels:4 (1 each per vane) 12 (3 each per cavity wall section) Duty Factor:6% Frequency sensitivity (thermal):33 kHz per 10C change in vane water temperature Frequency sensitivity (dimensional):1 MHz per 25 micron change in vane tip-to-tip spacing. SNS RFQ parameters

4. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage Material Choice Or Solid copper versus plated alternative Solid - Other vane type RFQ designs are predominantly fabricated from solid copper Copper machines poorly + low stiffness + heavy Copper is expensive Plated - Plating to cover joint interface Plating makes scratches worse Requires re-machining – e.g. on a diameter 50 by 450 bar, 50 microns in the centre would require 75 – 100 microns at the ends – a dog bone. Electroless nickel plate first. Expansion coefficients Conclusion – Manufacture from solid copper

5. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage CAD model is parameter driven

6. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage One quarter vane – machined component

7. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage One quarter vane – machined component

8. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage RFQ components

9. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage Complete model

10. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage Brazing details Braze Material:Nickel based eutectic Form of braze material:Paste + wire + shim Number of braze operations:1 Braze joint design:Radius groove + capillary (zero thickness) Number of joins:2 xEnd flanges 12 xKF40 flanges 24 xCooling channel plugs Braze company:Tecvac Turn-around-time:One week Approx cost:< £1000

11. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage Tecvac Wall work Heat Treatment have always followed a policy of investing in the most up to date equipment, in this case a 10 bar nitrogen pressure quench furnace with convection heating and the capability to carry out isothermal quenching. This enables steels such as H13 to be treated To maximum hardness with minimal distortion. Ion Implantation is cold surface treatment. The surface is bombarded with high-energy Nitrogen ions under vacuum. In many materials this increases the surface hardness, and because of the compressive stresses induced in the surface, fatigue resistance is also improved. Applications include:- surgical implants and instruments, paper knives, plastic moulding dies and screws. The majority of coatings supplied by the Wallwork Group are applied by Physical Vapour Deposition (PVD) using the electron beam evaporation method. This gives the smoothest and most defect free coatings of all the PVD methods. It is particularly suitable for high quality components where finish is of great importance. Applications include:- gas turbine blades, motorsport components, medical implants and high quality tooling.

12. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage C101 Copper

13. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage Finite Element Analysis T max = 50.3°CD max = 0.051mm Thermal calculations Gun drilling Deflection due to self weight

14. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage RFQ Rod Manufacture

15. UKNFIC meeting, 20 Oct 2005 – From Physics model to Engineering model Peter Savage