1. From Physics model to Engineering model

2. Vane type RFQ designs MOD_JPARC SNS JPARC
Japan Proton Accelerator Research Complex
Spallation Neutron Source
TRASCO
THIN
Trasmutazione Scorie

3. SNS RFQ parameters SNS: Spallation Neutron Source
Where: Lawrence Berkeley National Lab (LBNL)
RFQ type: 4 vane
Beam type: H-
Beam Acceleration: 65 keV to 2.5 MeV
Operating frequency: MHz
Beam current: 52 mA
Length: 4 x 3.7 metre sections
Cooling channels: 4 (1 each per vane)
12 (3 each per cavity wall section)
Duty Factor: 6%
Frequency sensitivity (thermal): 33 kHz per 10C change in vane water temperature
Frequency sensitivity (dimensional): 1 MHz per 25 micron change in vane tip-to-tip spacing.

4. Solid copper versus plated alternative
Material Choice Or
Solid copper versus plated alternative
Solid - Other vane type RFQ designs are predominantly fabricated from solid copper
Copper machines poorly + low stiffness + heavy
Copper is expensive
Plated - Plating to cover joint interface
Plating makes scratches worse
Requires re-machining – e.g. on a diameter 50 by 450 bar, 50 microns in the centre would require 75 – 100 microns at the ends – a dog bone.
Electroless nickel plate first.
Expansion coefficients
Conclusion – Manufacture from solid copper

5. CAD model is parameter driven

6. One quarter vane – machined component

7. One quarter vane – machined component

8. RFQ components

9. Complete model

10. Brazing details Braze Material: Nickel based eutectic
Form of braze material: Paste + wire + shim
Number of braze operations: 1
Braze joint design: Radius groove + capillary (zero thickness)
Number of joins: 2 x End flanges
12 x KF40 flanges
24 x Cooling channel plugs
Braze company: Tecvac
Turn-around-time: One week
Approx cost: < £1000

11. Tecvac
Ion Implantation is cold surface treatment. The surface is bombarded with high-energy Nitrogen ions under vacuum. In many materials this increases the surface hardness, and because of the compressive stresses induced in the surface, fatigue resistance is also improved. Applications include:- surgical implants and instruments, paper knives, plastic moulding dies and screws.
Wall work Heat Treatment have always followed a policy of investing in the most up to date equipment, in this case a 10 bar nitrogen pressure quench furnace with convection heating and the capability to carry out isothermal quenching. This enables steels such as H13 to be treated To maximum hardness with minimal distortion.
The majority of coatings supplied by the Wallwork Group are applied by Physical Vapour Deposition (PVD) using the electron beam evaporation method. This gives the smoothest and most defect free coatings of all the PVD methods. It is particularly suitable for high quality components where finish is of great importance. Applications include:- gas turbine blades, motorsport components, medical implants and high quality tooling.

12. C101 Copper

13. Finite Element Analysis
Tmax = 50.3°C
Dmax = 0.051mm
Thermal calculations
Gun drilling
Deflection due to self weight

14. RFQ Rod Manufacture