11-T Dipole Collaboration Review Cold Mass Fabrication and Tooling Procurement F. Savary, with contributions from B. Auchmann, E. Grospelier, S. Izquierdo Bermudez, M. Karppinen, F. Lackner, J.S. Murtomaki, H. Prin 27 September 2012 MSC-LMF

OUTLOOK From short models to full-scale prototypes/magnets The Large Magnet Facility at CERN Welding of the shrinking cylinder Tooling procurement Staffing plan Conclusions Cold Mass Fabrication and Tooling Procurement - FSY27/09/20122

FROM SHORT MODELS TO FULL- SCALE PROTOTYPES/MAGNETS 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY3

Milestones (short model – long prototype) Final design of the short model cold mass, 2 m (collared coil assembly in yoke + shells + end plates) 2-1 Demonstrator Magnet Model 1 FNAL (2 m) 2-1 Demonstrator Magnet Model 2 CERN (2 m) Preliminary design of prototype CM assembly (6.18 m) Dummy cable delivery (a unit length of bare Cu cable & another one insulated) to make 1 st practice coil in Cu Final design of short model CM validated by short model program (2 m) + 1 st long practice coil in Cu Real cable delivery (for prototype CM assembly, including practice coil in Nb 3 Sn) Final design review of prototype CM assembly (6.18 m) Design and procurement of tooling for prototype CM Prototype collared coil assembly Prototype CM assembly and cryo-magnet Cold test 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY4 : Q4-12 : Q3-13 : Q4-13 : Q3-13 : Q1-14 : By mid-14 : Started : Q1-15 : Q3-15 : Q4-15

THE LARGE MAGNET FACILITY AT CERN 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY5

Where? 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY6 180 Meyrin site, French territory B-180 – ~ 5500 m 2 – Cm area with 40 t crane – Cc area with 15 t crane B-183 – ~ 1500 m 2 – 30 t crane – Bb, machine shop and storage 183

Overview of the Large Magnet Facility A production line is available for horizontal assembly, in B-180 – Presently for NbTi magnets, nearly fully operational (a Q5 was assembled recently, and a MB is under construction) – From cable insulation to finished cold mass assembly – Coil length up to 14.5 m – Cold mass diameter up to 630 mm without major difficulty (welding- press currently equipped for 570 mm cold masses) – Including a dedicated area for the fabrication of bus bars (+ development of splices) in B-183 – 29 dipole and 7 quadrupole cold masses, removed from the machine (33 from sector 34), were repaired in B-180 Plan to adapt tooling for Nb 3 Sn magnets (see later in this ppt) A vertical assembling tour is also available in B-181 – For quadrupoles with inertia tubes concept – Fully operational (a Q7 was made there, now under finishing in B-180) 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY7

27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY8 180

27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY9 181

WELDING OF THE SHRINKING CYLINDER 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY10

Cradle design and coil stress Requirements regarding the coil / shell stress (1-1) – Coils in compression and shells in tension at cold & full current –  DESIGN = 160 MPa (shell stress at RT after welding) – Avoid overstressing the coils during the magnet construction  ALLOWABLE = 140 MPa – Close the yoke gap after welding of the shells, ensure that is stays closed at cold and full current Values are determined for a shell thickness of 12 mm 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY11 Load conditionCoil stress [MPa]Shell stress in [MPa] RT, after collaring75- RT, after welding the shells< K< 140< R P K, 11T< 140< R P0.2

Structural analysis was performed in order to: Verify if the cradle approach can introduce sufficient pre-stress in the shells Predict the achievable pre-stress in the shell based on new welding techniques (Welding -> thermal contraction -> pre- stress) Estimate the resulting pre-stress in the coil in each load-step Compare the results when introducing thicker shells 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY12 The load steps are as follows: Assembly at RT Cradle loading 375 t/m Welding contraction After welding-press opening Cooling to 1.9 K 1.9 K 11 T 1.9 K 12 T

27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY13 In order to estimate the effect of friction between shell and yoke two approaches were considered: 1.Introducing a friction based contact in ANSYS 2.Bonding the nodes over a 90˚ surface on the shell The shell pre-stress in ANSYS is implemented as a displacement constraint in the shell Closed gap is resulting in a reaction force over the entire gap height Coil pre-stress due to the various load-steps 2D Model - ANSYS 90˚ Bonded surface The results presented are for the frictionless and bonded contact approaches The implementation of pure friction would require the implementation of further load steps for realistic static to kinematic friction transition Model

27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY14 Stress in the shell (average), 12 mm thickness

27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY15 Stress in the shell (average), 15 mm thickness

Back in 2002 … 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY16 Welding of the LHC main dipole shells

27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY17 Stress in the coils Collaring

The Fjellman press How it was before refurbishment 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY18

The Fjellman press: Status Length:2.25 m effective Load capacity:330 t/m, or 750 t overall Number of jacks (top):28 jacks 6 independent circuits, see layout Reconstruction plan: – Extension and reinforcement work is ongoing – Cradles ordered, delivery expected beginning of November 2012 – Hydraulics ordered, delivery expected end of November 2012 – Welding equipment (power source, welding torch carrier and traveling chariot) will be rented for the first mock-up – Welding press operational first week of December 2012 – Welding of the first mock-up scheduled in the middle of Dec /09/2012Cold Mass Fabrication and Tooling Procurement - FSY19

27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY Reinforcement plates Cradle design for the 534 mm diameter single aperture magnet Top and bottom cradles need to be different: the bottom one has a slightly larger diameter Main frame currently under machining at an external company The loading/unloading mechanism will be based on a hydraulic lifting system 6 hydraulic circuits, surface of main plate = 2520 x 850 mm Existing hydraulic cylinders will be maintained and reused Semi-automated control system will be implemented Welding equipment from the company EWM will be tested during the first welding trials in Dec Main frame Status, cont’d 2160

Mock-up, to check whether we can build pre-stress 27/09/2012Cold Mass Fabrication and Tooling Procurement – FSY21 1-in-1Mock-up Existing CTF yoke R out = 255 mm Length = 500 mm Yoke gap shimmed in order to have 0.1 mm on outer and no gap on inner radial position Shell Material: AISI 304 L (R P0.2 = 220 MPa) Thickness: 12 mm thickness (fallback with 15 mm shells) Length: 1 m Aluminium cylinder will be used as dummy collared coil R out = 98 mm R in = 60 mm Radial shim 0.6 mm thickness +/- 30 degrees around the mid- plane Aluminium gap controller (no horizontal contact between gap controller and yoke) Measurements: Global stiffness of the assembly, spring constant Stress in shells (strain gauges, at the inner and outer surface to determine tensile and bending components) Yoke gap Lateral gap between upper and lower shells FE model from B. Auchmann Equivalent stress distribution using the existing CTF yoke and an aluminium cylinder to simulate the collared coil

Preliminary welding trials were done on plates mm 250 mm 12 mm 250 mm GAP Root face 50 mm (Datum points to measure the shrinkage) Aim: Determine welding parameters and details of the chamfer in order to get as large welding shrinkage as possible Welding parameters: -Material: AISI 304 L -Filler metal: (BOEHLER ASN5IG) -Shielding/Backing gas: Argon Welding process: -TIG + MIG (CERN Main Workshop, EN-MME) -Cold Arc (external company, EWM)

27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY23 Welding Process Backing strip? GAP (mm) Root face (mm) Average Shrinkage (mm) CERN MW 14xMIGYes xTIG + 3xMIGNo xTIG + 4xMIGYes Company EWM Cold ArcNo Cold ArcNo Cold ArcNo Cold ArcNo Cold ArcNo Cold ArcNo Cold ArcNo Cold ArcNo Cold ArcNo3±0.72.2±0.529±1 Mock up Preliminary welding trials on plates: summary

Welding of 1-in-1, and 2-in-1 models 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY24 Outer diameter:534 mm (for 12 mm shells)580 mm (for 15 mm shells) Total length:2168 mm (t.b.c.)2130 mm (t.b.c.) Expected date: 1-in-1 #1: Q in-1 #2: Q in-1 #3: as needed FNAL 2 in 1 Demonstrator (Q3-2013) CERN 2 in 1 Demonstrator (Q4-2013) Shells made of AISI 316LN (R P0.2 = 290 MPa) 1-in-1 2-in-1

TOOLING PROCUREMENT 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY25

Large size tooling procurement - preparation Reaction furnace – Market Survey done – IT-3861/TE launched in the end of September 2012 – Contract signature expected in December 2012 – Delivery to CERN expected in last quarter of 2013 Impregnation chamber – Market Survey, MS-3898/TE, launched on 14 September 2012 – IT to be launched in the middle of November 2012 – Contract signature expected in late January 2013 – Delivery to CERN expected in last quarter of 2013 Winding machine available – Needs to be adapted: length, winding mandrel, integration of additional spool, automat programming Curing-press available, curing molds to be developed Welding-press – New welding equipment and simpler seam tracking system will be integrated after validation of the process with the 500-mm long mock-up 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY26

Preparation work for winding Plan to launch in early October tooling modification (design then, construction) to allow fabrication trials (this is NOT the first practice coil made of Cu) Aim to resolve major issues at an early stage 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY27 Shorten the winding machine from 10 to 6 m Integrate a suspension for the second spool Fabricate winding mandrel and ancillaries From “short” To “long” B-927 B-180

STAFFING PLAN 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY28

The context … and the solution under preparation LMF staff (50) – 16 CERN staff + 1 fellow – 33 FSUs Most in the LHC tunnel for LS1 from April 2013 to June 2014 – Most already busy with the preparation work CERN launching IT-3895/TE for service contracts to selected companies, specialized in the design and construction of sc magnets – Envelope of 6 FTE, start progressively according to needs as from second quarter of 2013 – Typically 3 teams constituted of 1 academic engineer or physicist, 1 technical engineer or higher technician, and 1 experienced practitioner, with room for different scenarios – To work together with CERN staff, and prepare industry for technology transfer at an early stage of the project 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY29

CONCLUSIONS 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY30

Preparation of tooling has started, mainly the short welding- press, compatible with the design of the long welding-press Procurement process of long lead time tooling has started: reaction oven, impregnation system/chamber Plan to start very soon the modifications of the winding machine, and the execution of winding trials Plan to populate the magnet facility during LS1 has started Regarding the cold mass assembly drawings (6.18 m long prototype): all needs to be done, even if important input is available for the active part (from short model program) 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY31

SPARE SLIDE 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY32

Back in 2002 … Welding of the LHC main dipole shells 27/09/2012Cold Mass Fabrication and Tooling Procurement - FSY33