1. SQXF Cu Cable Winding Test at LBNL Dan Cheng Dec 17, 2013

2. SQXF Winding Test Uses the HQ winding mandrel as a baseline – FNAL-supplied mandrel spacer (120 mm -> 150 mm) eliminated need for significant tooling fabrication Parts rapid-prototyped in-house with Accura 60 – BEND design – Pole islands, wedges, spacers, end shoes Dec 17, 2013 D. Cheng2

3. HQ Winding Tooling Modifications Dec 17, 2013 D. Cheng3 FNAL supplied spacer to fill space from 120mm to 150mm dia modified for mounting to HQ mandrel

4. Winding Objectives Compare between copper and real cable – Winding behavior (parts shapes) – “Fluffiness” of coil in azimuthal direction Data gathering – Record mandrel rotation per turns – Observe effects of winding tension Dec 17, 2013 D. Cheng4

5. Winding Parameters Dec 17, 2013 D. Cheng5 CERN Cable HQ16UC0121D – 1.527 mm average thickness – 18.05 mm width – 0.59° keystone angle – Cable insulation Directly braided S2 Glass, 66 TEX, 636-sized ~146-150 µm, but LBNL 10-stack measurements pending to confirm thickness Winding tool used on all turns Initial 5 turns wound at low tension (~11-13 kg) Remaining turns – RE wound at low tension (11-13 kg) – LE wound at nominal tension (25-27 kg)

6. First Five Turns, LE, ~11 kg Tension Nb 3 SnCopper Dec 17, 2013 D. Cheng6

7. First Five Turns, RE, ~12 kg Tension Nb 3 SnCopper Dec 17, 2013 D. Cheng7

8. Turn 6, LE Nb 3 Sn, ~12 kg Tension Copper (wrapped spacers), ~27 kg Tension Dec 17, 2013 D. Cheng8

9. Turn 6, RE, ~12 kg Tension Nb 3 SnCopper (wrapped spacers) Dec 17, 2013 D. Cheng9

10. 2nd Spacer (T12), LE Nb 3 Sn, ~12 kg TensionCopper, ~25 kg Tension Dec 17, 2013 D. Cheng10

11. 2nd Spacer (T12), RE, 12 kg Tension Nb 3 SnCopper Dec 17, 2013 D. Cheng11

12. 2nd Spacer (T13/14), LE Nb 3 Sn, ~12 kg Tension ~72° angle Copper, ~25 kg Tension ~68° angle Dec 17, 2013 D. Cheng12

13. 2nd Spacer (T13/14), RE, 12 kg Tension Nb 3 Sn ~72° angle Copper ~74° angle Dec 17, 2013 D. Cheng13

14. End shoe (T22), LE Nb 3 Sn, ~12 kg TensionCopper, ~25 kg Tension Dec 17, 2013 D. Cheng14

15. End Shoe(T22), RE, 12 kg Tension Nb 3 SnCopper Dec 17, 2013 D. Cheng15

16. Final angle, after azim. compression ~67° Copper, LE~68° Copper, RE Dec 17, 2013 D. Cheng16

17. Summary of Turns 6-13 TurnTension kg Mandrel Ang. Notes Turn 6, LE25.48°*Wrapped spacer Turn 7, LE26.88°*Wrapped spacer 2 Turn 8, LE26.814° Turn 9, LE27.615° Turn 10, LE28.610° Turn 11, LE26.812° Turn 12, LE13.2*8°Wrong tension Turn 13, LE29.517°Spacer inserted; moved when winding Dec 17, 2013 D. Cheng17 TurnTension kg Mandrel Ang. Notes Turn 6, RE13.69°*Wrapped spacer Turn 7, RE12.718° Turn 8, RE13.618° Turn 9, RE10.412° Turn 10, RE12.76° Turn 11, RE13.610° Turn 12, RE13.614° Turn 13, RE12.79°Spacer inserted, did not move Lead End, ~25 kgReturn End, ~12 kg

18. Summary of Turns 14-22 Dec 17, 2013 D. Cheng18 TurnTension, kgMandrel Ang.Cable Ang. From horiz. Turn 14, LE25.912°67° Turn 15, LE26.38°69° Turn 16, LE26.313°71° Turn 17, LE24.912°70° Turn 18, LE25.411°70° Turn 19, LE2410°69° Turn 20, LE26.816°68° Turn 21, LE25.914°68° Turn 22, LE26.818°68° TurnTension, kgMandrel Ang.Cable Ang. From horiz. Turn 14, RE12.79°73° Turn 15, RE11.713°73° Turn 16, RE12.79°73° Turn 17, RE12.710°75° Turn 18, RE12.710°78° Turn 19, RE13.210°72° Turn 20, RE11.711°69° Turn 21, RE12.714°68° Turn 22, RE12.710°68° Lead End, ~25 kgReturn End, ~12 kg

19. Copper Cable Observations No popped strands – Same with the Nb 3 Sn winding test as well The cable did not form a concave shape at the ends, as observed in the Nb 3 Sn case Fluffiness of coil was virtually the same as with the Nb 3 Sn case – But cable seemed to want to “spring back” more, per technician’s observation Coil parts shape and fit seemed very similar between both cables wound with same tension Dec 17, 2013 D. Cheng19

20. Tension effects Higher tension did not seem to cause the cable to fit against the spacers better – Still needed significant azimuthal compression after all turns were wound – RE spacers fit tended to have similar gaps as seen in the Nb 3 Sn winding test – LE spacers also have similar gaps as seen in the Nb 3 Sn winding test Angle of cable against the pole/spacers, however, tended to be shallower with higher tension Dec 17, 2013 D. Cheng20

21. Summary The copper cable seems to behave reasonably well, compared with real cable – Parts shapes that don’t fit with one cable also didn’t seem to fit the other Without final curing press, it is still hard to confirm the final endshoe shape – Midplanes of both needed more clamping for position Dec 17, 2013 D. Cheng21