MICE RFCC Module Update Allan DeMello Lawrence Berkeley National Lab MICE CM25 at RAL, UK November 6, 2009

MICE RFCC Module 201 MHz RF Cavity Fabrication Update

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 3 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Progress Summary Cavity fabrication awarded to Applied Fusion in Feb Cavity body fabrication started in April 2009 Welding the stiffener ring to the shell and cutting the iris is complete Copper shells with the stiffener ring have been e-beam welded into 5 cavities Ports have been extruded into the perimeter of all cavities Welding the nose ring into the cavity irises is complete Welding the strut mounting posts onto the cavity is complete Welding of the cooling tubing onto the cavity is on going The first 5 cavities are scheduled to be delivered by end of CY2009

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 4 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Strut Mounting Post Cooling Tubing Cavity Component Parts Stiffener Ring Nose Ring Cavity Shells Extruded Port Flange

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 5 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Cavity Fabricator - Applied Fusion, Inc. Applied Fusion, Inc Republic Ave. San Leandro, CA Applied Fusion’s e-beam welder is a German made machine Applied Fusion has the machining equipment necessary to fabricate the complete RF cavity (minus spinning) Electron beam welding machine Milling MachinesInspection

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 6 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Title Here The stiffener ring is welded on to the half shell The iris is machined out Cavity Stiffener Ring

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 7 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 The cavity shells were inspected at LBNL and paired for best inside edge match Matched shells were e-beam welded into a cavity The cavity shells are oriented (clocked) to the stiffener rings with a pin E-beam Weld Shells into a Cavity

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 8 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Cavity is placed on a horizontal milling machine to bore the pilot hole for the extruded ports The shell alignment key is bored out as one of these pilot holes Bore Hole for Extruded Port

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 9 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Ports are extruded using LBNL provided tool The inside of the perimeter weld is ground to blend the two shell halves Port flange is e-beam welded to a machined port face Extruded Port

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 10 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 The nose ring is welded into the iris of the cavity The inside weld is ground down to blend the nose ring into the cavity wall Threaded holes for mounting the Be window to the cavity Nose Ring Welded into Cavity Iris

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 11 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 The cavities will be suspended inside the vacuum vessel with 6 struts in a hexapod arrangement Strut Mounting Post Strut mounting posts will have a Heli-coil thread insert for strength Strut mounting posts are TIG welded to the cavity

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 12 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Cooling Tubing Cavity cooling circuit uses one continuous tube No in vacuum cooling tube joints Tubing is TIG brazed to the cavity

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 13 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Cavity Cooling Tubing Finished Cavity cooling circuit completely TIG brazed onto cavity Tubing is fully leak checked

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 14 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Cavity Beryllium Windows Cavity Be windows are being fabricated by Brush Wellcome LBNL has received several finished windows

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 15 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Cavity Be Window Inside look at the Be window Cavity Be window alignment to nose ring looks good Some machining of the nose ring may be necessary to flatten mounting surface

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 16 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Cavity Progress Summary Most fabrication operations for the first 5 cavities (four plus one spare) are complete Cooling tube welding is on going Cavities are due to be delivered to LBNL by the end of the year

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 17 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Future Work Cavities must be “tuned” to each other for best center frequency (four cavities) by plastic deformation (will be done at LBNL) The inside surface of each cavity needs to be electro-polished (done at LBNL) Frequency tuner system testing and verification will be done on a finished cavity Exercise option to order the remaining 5 cavities (four plus one spare) for the second RFCC module

MICE RFCC Module Cavity Frequency Tuner Design Update

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 19 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Progress Summary Tuner design is complete ¼ scale model has been fabricated to test concept One full size tuner arm (for testing the system) is in fabrication Three RFQs for the bellows style actuator have been issued Control system components have been identified

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 20 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Cavity Frequency Tuners 24 Dynamic Cavity Frequency Tuners per Module Tuner Actuator Tuners operate in a bi-directional “push - pull” mode (±2mm) Tuning automatically achieved through a frequency feedback loop

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 21 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Designed around a flexure concept Stress levels seen in the FEA model are within material limits A bi-directional tuner and actuator design reduces bellows diameter and/or pressure requirements. Two Emerson ER3000 electronic pressure controllers [regulators] per cavity (one for each side of actuator piston) will control the 6 actuators Use of a high pressure regulator between N2 tank and supply lines to reduce supply pressure to 120 psi Cavity Frequency Tuner Design Overview

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 22 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Cavity Frequency Tuner Components Dual bellows vacuum sealing Dual – action tuner actuator Flexure tuner arm Screws fix the tuner to the cavity stiffener ring (both sides) Actuator is screwed into the tuner arm Fixed ‏ connection Forces are transmitted to the stiffener ring by means of “push-pull” loads applied to the tuner lever arms by the dual action actuator assembly Tuner/actuators are thermally independent of the vacuum vessel

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 23 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Actuator Design Actuator design incorporates a sealed enclosure between vacuum and air. Actuator is mounted to the tuner arm only Bellows allows angular movement for actuator Piston plates are joined at the perimeter Piston plates incorporate hard stops

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 24 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 MICE RF Cavity – Mechanical Design and Analysis Actuator inlet and outlet penetrate the rigid enclosure Actuator design incorporates push and pull actuation through holes in the center plate Actuator Design Details

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 25 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 FEA model with tuning arm and a test ring Tuning arm made from 3.0” stainless steel plate Cylindrical test ring replicates 1/6 of cavity Tuner System Analysis Model

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 26 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Tuner System Test Ring Analysis FEA of one tuner on 1/6 test ring cavity segment Test ring: 440 lbs applied force 1/6 th of measured cavity spring rate value 2mm) 1.04mm displacement per side (Ring ID=14.3”)

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 27 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Tuner System Analysis At the actuator the tuner arm displacement is 0.214” (~0.43” bi- directional) The cavity displacement is 1.05mm per side The maximum Von Mises stress at the flexure is 29.7Kpsi

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 28 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Tuner System Analysis The Von Mises stress at the flexure is 29.7Kpsi The input load by the air actuator is 800 lbs The tuner arm displacement is 0.214” (~0.43” bi-directional) [movement exaggerated] The cavity displacement is 1.05mm per side

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 29 Allan DeMello- Lawrence Berkeley National Lab – November 6, Bi-directional actuator design requires two electronic pressure controllers [regulators] (one for each side of actuator piston) 2. Regulators and pressure supply: a. Use high pressure regulator between N2 tank and supply lines to reduce supply pressure to 120 psi b. Actuator pressure controller: i. Emerson ER3000 electronic pressure controllers c. Use burst disc or safety valve in supply line d. A constant leak or valved-leak is required in actuator manifold to allow for relaxation of the tuner (design on going) Pressure System Requirements

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 30 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Emerson ER3000 electronic pressure controller ± 0.1% accuracy (over 110 psi range) 110 psi normal operating range (120 Max.) Remote computer controlled 16 required for two RFCC modules ($1, ea.)

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 31 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Designed around a flexure concept Stress levels seen in the FEA model are within material limits A bi-directional tuner and actuator design reduces bellows diameter and/or pressure requirements. Two Emerson ER3000 electronic pressure controllers [regulators] per cavity (one for each side of actuator piston) will control the 6 actuators Use of a high pressure regulator between N2 tank and supply lines to reduce supply pressure to 120 psi Cavity Frequency Tuner Design Summary

MICE RFCC Module Update – MICE CM25 at RAL, UK Page 32 Allan DeMello- Lawrence Berkeley National Lab – November 6, 2009 Schedule Summary