Oct. 12, 2006 Undulator Breakout Dean R. Walters 1 Vacuum System Undulator Vacuum System Dean R. Walters Soon-Hong Lee, James Bailey, James Morgan, Dana Capatina, Scott Doran, ANL Lou Ann Tung, LLNL

Oct. 12, 2006 Undulator Breakout Dean R. Walters 2 Beam Finder Wire Chamber Vacuum System Vacuum System Undulator Vacuum System

Oct. 12, 2006 Undulator Breakout Dean R. Walters 3 BFW In Situ- Short Break BFW Undulator Beam Girder

Oct. 12, 2006 Undulator Breakout Dean R. Walters 4 BFW Assembly Mounted on Adjustable Support Adjustable Mounting Support Vacuum Pump Connector (2.75” Conflat Flange) Card Position Monitor (Limit switches) Air Supply Shut Off Valve Pneumatic Solenoid Valve Precision Screw Electrical Connectors for Wire Signals Vacuum Chamber Connection Flange (NW-50 CeFix w/Clamp) Beam Port Pneumatic Cylinder Alignment Fiducials Frame Compression Spring Positioner Potentiometer Housing

Oct. 12, 2006 Undulator Breakout Dean R. Walters 5 BFW Prototype Setup Kinematic Stop Plates Engaged Precision Screws Pneumatic Cylinder “Keyence” Sensors Supports Read Out Air Supply Line 70 psi Vacuum Line Bellows Fixed Frame Movable Assembly Vacuum Chamber

Oct. 12, 2006 Undulator Breakout Dean R. Walters 6 BFW Prototype Results Vertical Repeatability: +/-7 Microns Horizontal Repeatability: +/- 14 Microns (Extrapolated to account for lever arm) Adjustability: +/- 2 Microns Required Force on Kinematic Stop: 20 lbs. Slide Rod Clearance: 0.020” Top Locking Screws: Lock Washers OK

Oct. 12, 2006 Undulator Breakout Dean R. Walters 7 Assemblies and Cross Sections Assembly Vacuum Chamber Flange Locating Pins Bellows Flange Shielding Cut-out BFW Flange Seal Vacuum Flange Beam Tube Spider

Oct. 12, 2006 Undulator Breakout Dean R. Walters 8 BFW Production Schedule

Oct. 12, 2006 Undulator Breakout Dean R. Walters 9 Beam Finder Wire Final Design Review Report A final design review of the APS/LCLS Beam Finder Wire (BFW) was held on September 20, 2006 at Argonne National Laboratory. Recommendations: The ANL/SLAC team should proceed with the fabrication of the Beam Finder Wire Assembly and the BFW Support Assembly excluding the Wire Card Assembly. The Wire Card Assembly should have a design review after final material selections are complete.

Oct. 12, 2006 Undulator Breakout Dean R. Walters 10 X-Adjustor Z-Adjustor Support Assembly Production Vacuum Chamber Ass’y Vacuum Chamber Assembly

Oct. 12, 2006 Undulator Breakout Dean R. Walters 11 Measurement results of magnetic permeability (  r ) 1.Anneal conditions Vacuum pressure at 1.0 x Torr 1,750 º F for 30 minute soaking on 20Cb-3 and 1,950 º F for 30 minute soaking on the other types Rapid Nitrogen gas quenching 2.316LN had stable permeability values of less than 1.010, even if cold-works and welding S and Nitronic 40 had increased in permeability after welding significantly. 4.20Cb-3 had acceptable permeability values less than (most less than 1.010) and good welding characteristics (less heat-affected zone) 5.Nitronic 33 and 20Cb-3 had increased in permeability after annealing. MaterialAs-received condition After vacuum annealing After machining & forming After TIG welding After final machining 316LN1.002 a (1.004 b )1.003 a (1.003 b ) a (1.003 b )1.008 c (1.003 d ) 310S1.057 e (1.005 f )1.036 e (1.003 f )1.033 e (1.003 f )1.042 e (1.018 f )1.051 c (1.007 d ) 20Cb e (1.008 f )1.008 e (1.015 f ) e (1.011 f )1.018 c (1.009 d ) Nitronic 33 (1.002 g )1.022 e (1.006 f )1.030 e (1.012 f )1.030 e (1.023 f )1.126 c (1.033 d ) Nitronic e (1.003 h )1.003 e (1.004 h )1.005 e (1.004 h )1.019 e (1.052 h )1.081 c (1.048 h ) Initial Calibration, 1.27± Note on thickness a : 1.99 mm, b : 6.65 mm, c : 0.5 mm, d : 6.0 mm, e : 1.59 mm, f : 6.35 mm, g : 7.94 mm, h : 4.76 mm

Oct. 12, 2006 Undulator Breakout Dean R. Walters 12 Measurements of the changes of applied magnetic fields Sample chambers under APS undulator "A" A 3-inch-long sample vacuum chamber was inserted Into a hybrid permanent magnet undulator with a 3.3 cm period and 8 mm min. gap To Investigate high magnetic field influence to the relative magnetic permeability Peak of applied magnetic field: ~ 1.2 T  B/B < 1.5 x10 -4 Undulator A 8.0 mm Sample chamber Hall probe holder

Oct. 12, 2006 Undulator Breakout Dean R. Walters 13 Fabrication Processes SST Plate, End Cap (144” x 7.5” x 1”) (144” x.5” x.25”) 20Cb-3 Seam Welding Final Machining Cleaning/Baking Milling/Polishing SST Sheets (144” x.75” x.120”) 316LN SST Polishing/Milling Coating

Oct. 12, 2006 Undulator Breakout Dean R. Walters 14 Prototype Vacuum Chambers Compound screws (Brass Screws & SST ) Vacuum Chamber NW 50 Flange -Clamp Type (316L SST) Top & Bottom Strips (316LN) Chamber Strong-back (20Cb-3) End Cap (20Cb-3) Prototype A Prototype B Top & Bottom Strips (20Cb-3) Chamber Strong-back (316 SST) End Cap (20Cb-3)

Oct. 12, 2006 Undulator Breakout Dean R. Walters 15 SUT Machining Results Material: Austenite stainless steel 316 Supplier: Walco Tool & Engineering Parallelism of chamber surfaces (0.100 mm): mm Thickness of chamber (6.00 ~ 6.08 mm) : max mm Straightness of chamber edge (± mm) : max mm bowed Vibratory or thermal stress relief is required, which may restore the original properties of the base metal E H

Oct. 12, 2006 Undulator Breakout Dean R. Walters 16 Prototype B Machining Results Material: Austenite stainless steel 316 Supplier: Dial Machine Inc. (measured Aug. 8, 06) No attempt was made to tweak in, or adjust, the constrained condition to improve the results. Flatness of nose bottom surface in the clamped condition (0.100mm): 0.314mm Parallelism of nose bottom surface to strongback bottom in the clamped condition (0.100mm): mm Parallelism of nose top surface to nose bottom surface in the clamped condition (0.100mm): mm Straightness of chamber edge (180.0± 0.20mm) : ~179.70mm (0.160mm bowed) Thickness of chamber every 12” in the clamped condition (5.0±.08mm) : 4.945~5.112mm Flatness of the surface of machining fixture in the strongback clamped condition: 0.04mm Flatness of the bottom surface of strongback in the free state: 1.143mm

Oct. 12, 2006 Undulator Breakout Dean R. Walters 17 Polishing of Stainless Steel Samples of True #8 stainless steel sheets from Pacific Plus Inc. of Dallas, TX / Hwa Yang Stainless Steel Group in China. True #8 and super #8 are trademarks of Pacific Plus International, Inc. 1.5 mm thick 316 SST sheets (1 ft x ft) and 0.5 mm thick 304 SST sheet (4 ft x 8 ft) were bought to evaluate the impact of manufacturing operation on the surface finish. Samples were polished at Fine Art Inc. and Polished Metals Limited. Measurements Used Tencor Alpha-Step to obtain a 2D surface profile. Used MicroXAM RTS surface profiler (White light interferometry) MicroXAM RTS from

Oct. 12, 2006 Undulator Breakout Dean R. Walters 18 Sample: #PLM 2Mode: PMObjective: 50xSize: x mm 2 # 8 r(z): mm; h rms : 27.9 nm x’ rms : 14.4 mrad; z’ rms : 3.6 mrad Sampled Data (1024x1024)Lineout (x: #200; z: #300-#400)Full Spectrum (1024x1024) Sampled Data (500x500) Lineout (x: #200; z: #300-#400)Full Spectrum (500x500) Sample: #PLM 2Size: x mm 2 WLI AFM r(z): -907 mm; h rms : 13.5 nm x’ rms : 24.4 mrad; z’ rms : 8.2 mrad Evaluation of Roughness Scans - Polished For wakefield considerations, the beam- (or z-) direction is the most important and all measurement results are within tolerance, i.e., have rms derivatives in z of less than 10 mrad.

Oct. 12, 2006 Undulator Breakout Dean R. Walters 19 CO 2 Laser Weld Prototyping Inspection Results for Sample 3 Seal weld Intermittent weld Groove

Oct. 12, 2006 Undulator Breakout Dean R. Walters 20 Laser Welding/Final Machining Prototyping 42” Prototype After Laser Welding and Before Final Machining

Oct. 12, 2006 Undulator Breakout Dean R. Walters 21 CO 2 Laser Weld Prototyping 42” Vacuum Chamber Prototype Fixturing for end cap welding Welding end cap Fixturing for strong back welding Welding strong back

Oct. 12, 2006 Undulator Breakout Dean R. Walters 22 Final Machining Prototyping Machined to red line both sides Vacuum Chamber Gap Six Inch Long Prototypes Actual Weldment

Oct. 12, 2006 Undulator Breakout Dean R. Walters 23 Final Machining Prototyping Machining of 6” Long Prototypes 1” Dia. End Mill Dial Indicator T/C Measurement

Oct. 12, 2006 Undulator Breakout Dean R. Walters 24 Final Machining Prototyping Preliminary Inspection Results for the 42” Prototype <0.002” Flatness & <0.002” Tolerance on Thickness

Oct. 12, 2006 Undulator Breakout Dean R. Walters 25 Coating Basics

Oct. 12, 2006 Undulator Breakout Dean R. Walters 26 Pictures of test set up operating Coating in a 35 mm SST Tube

Oct. 12, 2006 Undulator Breakout Dean R. Walters 27 Test set up operating Coating inside a 12.7 mm Glass tube Coating inside a 7.9 mm Glass tube

Oct. 12, 2006 Undulator Breakout Dean R. Walters 28 Measurements of samples Samples Measure thickness of 560 nm, 240 nm, & 130 nm Deposition Rate of 23 nm per minute

Oct. 12, 2006 Undulator Breakout Dean R. Walters 29 Prototype Development Strongbk. MayJuneJulyAug.Sept.Oct.Nov.Dec.Jan.Feb MayApr. P.O. End Cap Side Walls Weldment Strongbk. End Cap Side Walls Weldment Strongbk. End Cap Side Walls Weldment Strongbk. End Cap Side Walls Weldment Prototype A Strongbk. End Cap Side Walls Weldment Prototype B Strongbk.Proc. 316 L & Initial Mach.P.O. End CapProc. 20Cb-3 & Initial Mach. Side WallsPolish Sheet Intl. Mach. Weldment Fab. Fix. & Weld Mach/ Coat 20Cb-3 Mach. Proc. 20Cb-3 & Initial Mach. Intl. Mach. Polish Sheet Fab. Fix. & Weld Mach/ Coat

Oct. 12, 2006 Undulator Breakout Dean R. Walters 30 Prototype Development MayJuneJulyAug.Sept.Oct.Nov.Dec.Jan.Feb MayApr. 42” Prototype PartsProc. 304 SS & Mach. Fixtures (Weld)Design & Fab. AssemblyWeldMachCoat Laser Weld Development 6” ANL 18” SamplesCO Vendors Final Mach. Development 6” ANL Fixtures (Mach) Design & Fab.

Oct. 12, 2006 Undulator Breakout Dean R. Walters 31 Bench Test Prototype Development MayJuneJulyAug.Sept.Oct.Nov.Dec.Jan.Feb MayApr. Equipment Design Consultant Coating Development AgreementPlace PO1 St ProcureAssy Power Supply Loan AgrShipInstall Process Dev 42” Prt Full Size Setup Part #2

Oct. 12, 2006 Undulator Breakout Dean R. Walters 32 Chamber Schedule

Oct. 12, 2006 Undulator Breakout Dean R. Walters 33 Chamber Design Review The LCLS undulator vacuum chamber and system were reviewed by a committee composed of John Grimmer, APS, Nadine Kurita, SLAC, Allan Rowe, FNAL, and John Noonan, ANL, chair on September 27 and 28, 2006 Schedule The schedule for fabrication and delivery of vacuum chambers for the undulator vacuum system is tight, especially for the undulator vacuum chamber. This is a complex part with stringent physics requirements, especially the surface finish. Aspects of the chamber are demonstrated, but a full-size prototype will not be complete until December, The Undulator Vacuum Chamber There are no technical barriers to fabrication of the chambers. However, there are tooling and detailed fabrication issues that need to be answered in order for production to proceed. Successful chamber fabrication will be a significant accomplishment. The physics are stringent Fabrication of the full size prototype chamber is essential and the engineers should have all the APS and LCLS support that they need to complete the fabrication. The full size prototype will determine vacuum integrity, outgassing rates for the chamber, coating surface finish, and dimensional straightness. It is important to perform a test in which the full size chamber is installed in an undulator and its straightness measured. The survey groups need to be involved in the tests and certify that the installation procedure is reasonable. Magnetic measurements need to be repeated on the 20Cb-3 steel. The 20Cb-3 material has no apparent pedigree in demanding vacuum and magnetic applications. The prototype has not yet been welded leak tight and will clearly be "worse" than 316LN in magnetic performance, although the effect of the difference is debatable.

Oct. 12, 2006 Undulator Breakout Dean R. Walters 34 Vacuum System Calculations In past hand vacuum calculations have been used to estimate the vacuum system performance Recently a collaboration with LLNL has been established to provide calculations. Below are the results obtained at this point. The next analysis will include: -Add in the turbo and roughing pumps (with S(p)) in the long break and an ion pump in all three breaks -Put in the time-dependent outgassing rate for stainless steel (already have fit) -Put in the different rates for copper and aluminum

Oct. 12, 2006 Undulator Breakout Dean R. Walters 35 Long break layout (Short break is the same but without the valve spool)

Oct. 12, 2006 Undulator Breakout Dean R. Walters 36 Pressure profile with one ion pump on the long break with one undulator section  z = 1 cm All surfaces outgas at 1.6 x T-l/s/cm 2 cm One undulator sectionLong break

Oct. 12, 2006 Undulator Breakout Dean R. Walters 37 Conclusions BFW Design, testing, and review have been completed. Committee has agreed that it is ready to enter production Chambers This has not progressed as expected. The Strongback delay has rippled through the prototype schedule and it impacts the production schedule. The Design Review Committee has agreed that the Strongback can enter production, but testing is needed on the full sized prototypes to continue with the production of the whole weldment. These Prototypes must be done before the end of January so that the production units are not impacted.

Oct. 12, 2006 Undulator Breakout Dean R. Walters 38 CO 2 Laser Weld Prototyping 42” Vacuum Chamber Prototype Results in Constraint Condition 0.002” 0.000”0.001” 0.000” 0.001” 0.000”0.001” 0.000” 0.002” 0.001” ” Flatness Variation Along Center of Wall Sheet Across Sheet Flatness <0.001”

Oct. 12, 2006 Undulator Breakout Dean R. Walters 39 Vertical Adjustment Screws (14) Vacuum Chamber alignment

Oct. 12, 2006 Undulator Breakout Dean R. Walters 40 Test Set up Cathode Guides Straightening of Cathodes Tensioning of Cathodes Vertical positioning 42” chamber Full size setup Vertical Coating Stand On Going Work