1. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 1/24 EuCARD-WP7-HFM ESAC Review of the dipole design Engineering Design Pierre MANIL CEA/iRFU/SIS January 20, 2011 @ Saclay

2. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 2/24 Contents Inputs Magnet detailed geometry ► Overview ► Ends ► Layer jump ► Cable needs Structure detailed geometry ► Overview ► Focus ► Masses Detailed engineering ► Materials choice ► Tolerances and machining

3. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 3/24 Magnetic inputs [1] ► Cable properties ► 2D magnetic layout Mechanical inputs [1] ► 2D stress analyze ► 3D conceptual study Constraints [2] ► Specified straight section > 700 mm Source: FRESCA2 test station requirements ► Overall magnet length = 1500 mm Source: EuCARD contract ► Specified aperture = Φ100 mm Source: EuCARD contract ► Reaction furnace section = 350 x 200 mm Inputs

4. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 4/24 Magnet detailed geometry [Draftsman: Jean-François Millot]

5. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 5/24 Overview 1.5 m – long Straight section length > 700 mm ✓ ✓

6. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 6/24 Preliminary test HW-bend is OK with this cable [3] Ramp angle up to 25° possible HW ‘safe radius’ ~ 500 mm Circular end is OK See Françoise’s talk ~R500 Bare copper cable, HFM dimensions Variable ramp angle Versatile HW-bend geometry 3 options for the end

7. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 7/24 Geometrical definition of the ends [2] ► R > 500 mm (test) ► L ss > 700 mm ► L os > 0 ► h tot < 200 mm ► aperture 61 mm Ends α = 17°, R variesR = 700 mm, α varies

8. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 8/24 17° ramp, R = 700 mm => L os = 24 mm, L ss = 730 mm (layer jump included) Can be compared to HD2 [4]: 10° ramp, R ~ 350 mm Slight differences between lead/return end Ends details

9. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 9/24 Several options have been considered [5] ‘HW soft’ is selected Layer jump 42 36 42 36 43 42 36 35 (flat)   ✓

10. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 10/24 Layer jump details Straight section (= 700 mm) ‘Chicane’ in the top layer (over 28 mm) HW-bend connection (in a plane) to the bottom layer Layer jump 3-4 [CATIA drawing]

11. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 11/24 ~ 1 km of cable for the dipole ~ 50 km of strand Cable needs CABLE NEEDS Sub-element Theoretical cable length (m) + 3% margin Double-pancake 1-2223230 Double-pancake 3-4253260 1 POLE476490 FULL DIPOLE952981 in one piece 4 pieces of cable

12. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 12/24 Shell-based structure principle from Berkeley [6] Additional calculations are still needed Connections (out of the structure) to be designed Assembly process in Maria’s talk Structure detailed geometry [Draftsman: Pascal Labrune]

13. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 13/24 Overview Iron yoke 70 mm-thick aluminum shell Axial pre-stress system COIL PACK Coils100 mm aperture (no bore tube) Bladders and shims Material colors: Coil Steel Aluminum Iron Titanium Aluminum-Bronze Insulation (Tooling) 1600 mm 2066 mm

14. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 14/24 Focus: coil pack Flexible insulation (~1 mm) Vertical Pad 171 iron laminations: MAGNETIL (LHC iron) 5.8 mm-thick Horizontal Pad in one steel piece 5 mm-thick steel plates No bore tube Rails, pole and horseshoes potted with the coil Steel wedges

15. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 15/24 Focus: poles Contact over 6 mm Groove for midplane shims Layer jump template Longitudinal positioning notch Vertical contact here Axial stop for midplane shim 500 MPa σ eq peak @ 13 T [1] Titanium pole Soft iron pole

16. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 16/24 Focus: yoke Notches on both sides for bladder positionning Rod holes Longitudinal Weld Pinning holes x3 Yoke half 250 iron laminations: MAGNETIL (LHC iron) 5.8 mm-thick

17. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 17/24 Focus: axial compression system Φ~30 mm aluminum rods Steel end plates (~100 mm) TO BE DIMENSIONNED Hydraulic pre-stress tooling of the SMC system [7] Clearance for key insertion Coil/Plate contact offset with grub screws

18. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 18/24 Focus: bladders 14 bladders allowed [6] 1.6 m-long (or 2 x 0.8 m-long) Target pressure ~100 bars Conical lock (700 bars) Removable insertion shim 2 steel sheets (0.3 mm-thick) Water arrival Laser-weld all along

19. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 19/24 Focus: keys 6 keys 1.6 m-long (or 2 x 0.8 m-long) Versatile thickness (stack of shims) Pin Round chamfer all along for insertion Stack of shims (0 to 1000 μm) Nominal steel keys ‘sandwich’ (3+3 mm) Handling hole

20. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 20/24 Magnet ~ 300 kg (copper density) Structure ~ 10 300 kg (without magnet) Masses Sub-elementMaterialQuantityTotal mass (kg) Double-pancake 1-2Insulated Nb 3 Sn*2138 Double-pancake 3-4Insulated Nb 3 Sn*2156 Lower poleTitanium238 Upper poleIron257 HorseshoesSteel436 RailsAl Bronze494 Midplane shimSteel221 Horizontal PadSteel2640 Vertical PadIron + Steel21047 WedgeSteel2152 YokeIron + Steel26 950 ShellAluminum11 020 Axial rodsAluminum421 End platesSteel2200 KeysSteel627 TOTAL10 597 Potted poles: 519 kg Coil pack: 2 379 kg * See Philippe’s talk

21. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 21/24 Materials choice MaterialParts 2D peak stress RProperties [8] MPa Nb 3 Sn with NED insulationCoil142[150] Magnetic steelTop pole345*> 600 MAGNETIL iron laminationsYoke / Y-Pad410*> 600 5,8 mm-thick sheets available at CERN Steel AISI 316LX-Pad / Y-Pad315490-690 Solderable, amagnetic, resistant to corrosion Titanium Ti-6-Al-4VBottom pole500900 Al 2014 T651 (A-U4 SG) Shell205 435 Solderable, machinable, limited resistance to corrosion Al 7075 T651 (A-Z5GU)485 Machinable, limited resistance to corrosion, limited solderability 2D stresses are supported 3D stresses to be checked Peak stress values from Attilio Milanese [1] * = corner value

22. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 22/24 Mostly conventional shape tolerances Refined tolerances on key insertion planes and bladder notches Lamination machining process Outer shell: ► Outer diameter φ1140 mm ► Overall length = 1600 mm, can be divided in several parts ► Influence of the cylindrical tolerance between shell and yoke? ► Can we allow roll welding? Tolerances and machining

23. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 23/24 Thank you

24. HFM High Field Magnet, Engineering Design, 20/01/2011, Pierre Manil, 24/24 References [1] Fresca2 conceptual design A. Milanese talk given this morning [2] EuCARD-HFM dipole specification and baseline parameters MPWG EuCARD-HFM internal note, January 2011 [3] EuCARD-HFM : Rapport sur les essais de cintrage des têtes de bobine en configuration bloc F.Rondeaux, A. Przybylski, P.Manil CEA report, ref. SAFIRS 00152 A, June 2010 [4] Design of HD2: a 15 Tesla Nb3Sn Dipole with a 35 mm Bore G. Sabbi et al. IEEE Trans. Appl. Supercond., 2005 [5] 21-10-10 - Status of the turns-by-turns model P. Manil, J.-F. Millot EuCARD-HFM internal note, October 2010 [6] The use of pressurized bladders for stress control of superconducting magnets S. Caspi IEEE Trans. Applied Superconductivity, vol. 16, Part 2, pp. 358–361, June 2006 [7] Mechanical Design of the SMC (Short Model Coil) Dipole Magnet F. Regis et al. IEEE Trans. Appl. Supercond., Vol. 20, 2010 [8] NF E 01-000 and NF A 50-451