LMQXFA Cold Mass Assembly Antonios Vouris Fermilab February 3, 2016

2 OUTLINE Antonios Vouris, MQXF Alignment – 3 Feb Fermilab Magnet Receiving Inspection Magnet Alignment Shell Stress Analysis He Shell Installation Sequence Cold Mass Handling He Shell Welding NDE Summary

3 Magnet Receiving Inspection Antonios Vouris, MQXF Alignment – 3 Feb Fermilab Visual Geometry: OD & Length Electrical Checkout Vertical and horizontal straightness Twist

4 Cold mass alignment MQXFA Dedicated work station for alignment fixture – anchored, leveled and surveyed (laser). Align & verify magnet centers with LBNL yoke tooling block following similar procedure.

5 He shell Installation Antonios Vouris, MQXF Alignment – 3 Feb Fermilab Install shell tack blocks with fasteners (Stainless?). Fit and weld Back up strip to tack blocks.

6 He shell installation Antonios Vouris, MQXF Alignment – 3 Feb Fermilab Dimensional inspect shell half (shell rolling tolerance +/- 1.5 mm possible +\- 3mm) Fit half shell to aligned magnets Draw shell snug with rolling fixtures to tack shell to back up strip – use 4 fixtures spaced 400 mm to 500 mm apart and tack between fixtures. Use rolled shims from same material to center magnet in clamp fixture.

7 Shell stress - 2 point lift Antonios Vouris, MQXF Alignment – 3 Feb Fermilab Von Mises stress 4.6 MPa (667psi) Max. Max deflection:.12mm

8 Rolling the cold mass Antonios Vouris, MQXF Alignment – 3 Feb Fermilab Drive unit Weld rollers mounted on weld tables anchored, leveled and surveyed.

9 Final shell welding Antonios Vouris, MQXF Alignment – 3 Feb Fermilab Cold mass is returned to work station with saddles Alignment is checked again with LBNL yoke fixture. Stretch wire measurement is performed right after surveying with yoke fixture and measurement compared. Install instrumentation (and Bus?) Electrical check out Clamps used again for drawing upper shell snug before tacking. Longitidunal TIG done simultaneously on both seams. Stretch wire measurement is done after each pass.

10 NDE Antonios Vouris, MQXF Alignment – 3 Feb Fermilab Stage for NDE XRAY – a spot may be required for reduction in wall thickness. Spot taken at mid section between gaskets Liquid Penetrant testing – all nozzles welds on shell/end domes

11 End Domes End domes machined and ID cut to true ID (extra forming stock allowed to ID) Mill penetrations for Beam Tube and heat exchangers Nozzles welded to heads Head weldment fixture and aligned to shell. Install Beam tube aligned and welded with fixture

12 Summary/questions Antonios Vouris, MQXF Alignment – 3 Feb Fermilab Are any magnetic field measurements required for incoming inspection or during fabrication process? How do we verify welding of shell to tack blocks do not add stress to yoke? Are fiducials needed outside the He Vessel? How will the cold mass interface with the vacuum vessel? What are the vessel flange interfaces and or sizes? Weld shrinkage is typically ~1/2t or.18” (4mm) for a joint of 5/16” (8mm). Two welds shrinking a min. of 1/32” (.8 mm) ea. will reduce the SS shell ID ~.04” (1 mm) Cold mass alignment will depend on individual magnet tolerances. Any movement after alignment will be due to handling but can be minimized with proper fixture. Assume welding to cause minimal magnet movement but also expect welding to draw shell to magnet. Shell length at 9506 mm (375”) may be an issue to procure as one length due to forming capacities by Fermilab vendors.

13 Extra Slides Antonios Vouris, MQXF Alignment – 3 Feb Fermilab Total Turning Capacity(2 Idlers) in Tons25 Turning Capacity(1 Idler) in Tons20 Weight Capacity, Each Unit, in Tons8.5 Motor Horsepower2 Voltage230 or phase Speed Range, IPM7-58 Wheel Face Width7” Tires Per Axle1 Maximum Working Diameter15’ Minimum Working Diameter6” Tire Diameter18” Wheel Center Spacing23 ½”, 41”, 58”, 75” Height to Top of Tire22 ½” Control Cable Length Optional (30’ Extension Available) 30’ Power Unit Length133 ½” Power Unit Width33” Idler Unit Length106” Idler Unit Width24“ Power Unit Shipping Weight2,200lbs Idler Unit Shipping Weight850bs Total Shipping Weight (Approx.)3,050lbs R500 Heavy Duty Turning Roll Detailed Specifications