1. Analytical Cost Model (16 T dipole)
T. Martínez, J. Munilla, F. Toral - CIEMAT
Progress Meeting #, November 2nd, 2016

2. Preliminary main cost drivers
Manufacturing of main components (strict fabrication tolerances):
End spacers
Cu-Alloy wedges
Iron yoke laminations
Iron pads laminations
Master keys
Conductor and wedges insulation
Impregnation
Ground insulation
Plasma coating insulation
Aluminum shell
Axial rods
End plates
Quench Heaters 2

3. Status of the analytical study
End Spacers:
Raw material: 316L
Production process: 3D printing
Reference price (11T): 1.100€ (end saddle)+4.200€=5.300€ per coil
Estimation for 16T :
Inner layers: 5.300× =4.417€
Outer layers: 5.300× 103,8 60 =9.169€
2 coils and 2 apertures: € per magnet
High price: another alternative must be considered
Scaling by volume 3

4. Status of the analytical study
End Spacers:
Suggestion from CERN main workshop:
Consider another material for fast machining
No excessive grain growth during heat treatment
Non magnet
Fulfil mechanical/structural specifications
Stefano Sgobba will be contacted for recommendations
Couple of tons of test melt will be requested to a steel company (to be discussed/budget??) 4

5. Status of the analytical study
Cu-Alloy Wedges:
Raw material: CEP DISCUP C3/30
Production process: extrusion
Initial assumption: consider just 2 different wedge profiles instead of the real 10 different ones
One dipole cold mass contains approximately 560 meters of copper wedges of each different profile. The wedges shall be delivered in 3500 mm long pieces. Consequently in one cold mass there are 160 copper wedges pieces of each profile (considering initial assumption). 5

6. Status of the analytical study
Cu-Alloy Wedges:
Quotation for these 2 wedges profiles has been asked to Luvata and Buntmetall:
Wedge 10
Wedge 6
Wedge 10
Wedge 6 6

7. Status of the analytical study
Cu-Alloy Wedges:
Luvata proposal:
Half length: 1750 mm long pieces
Manufacturing tolerances change (+/-20 µm fabrication tolerances requested)
thickness +/- 0,03 mm
width +0,04 /-0,06  mm
First cost estimation:
Tooling: 1.500€ per profile
Material: €/kg 7

8. Status of the analytical study
Cu-Alloy Wedges:
Our estimation basis on Luvata’s figures:
561 kg of material per magnet
Cost estimation (considering 10 different profiles):
Tooling: x 10= € per 10 wedge profiles (life cycle of tooling?/price of maintenance?)
Material: 561kg x 90 €/kg= € per magnet
COST DRIVER
Mat.
Area mm2
quantity 1 dipole mass pcs
length mm
quantity 1 dipole mass meter
kg/m
quantity 1 dipole mass kg
Wedge 6
62,32 64
1.750
112
0,56 63
Wedge 10
60,89
0,55 61
Wedge 1
43,77
0,39 44
Wedge 2
39,55
0,35 40
Wedge 3
47,62
0,43 48
Wedge 4
49,54
0,44 50
Wedge 5
41,95
0,38 42
Wedge 7
78,27
0,70 79
Wedge 8
51,24
0,46 51
Wedge 9
83,97
0,75 84
559,12
mm2
561 8

9. Status of the analytical study
Cu-Alloy Wedges:
Luvata proposal:
Prototype phase: 10 pieces (1.750mm long) of each profile wedge
Production Phase: tolerances, measurements of dimensions, mechanical properties and testing, straightness, surface quality and other mechanical items to be agreed (no price quotated#90€/kg estimated but not confirmed)
Buntmetall response:
Equipment of hydrostatic pressure does not allow them to use CEP DISCUP C3/30 (CEP DISCP-powder metallurgical process and Buntmetal alloys- melting&casting )
Another alternative under development:
Our requirement: Yield strength of 200MPa after a heat treatment at 650°C
Information requested by the company:
dwell time at 650°C: 10 hours?
the required electrical conductivity? (to be discussed) 9

10. Status of the analytical study
Plasma Coating Insulation:
2000€ per set of 14 parts for the plasma coating of the MQXF (1 coil)
Scaling by areas as Etienne Rochepault has suggested:
MQXF aperture: 150 mm
Dipole/quadrupole:
4 layers/2 layers
2 coils per magnet
2 apertures
Final price: € per magnet
Is it possible another kind of insulation for the end spacers? (cheaper)
CERN main workshop suggested to contact vacuum group
1/3 x2 x2 x2 x2 10

11. Status of the analytical study
Iron yoke and iron pad laminations:
Raw Material: ARMCO
Production process: Fine blanking
Manufacturing tolerances to be decided
Which is the optimum thickness to reduce the cost?
Laminations of 5,8 mm could be a good starting point
Optimum thickness advice will be request to BNL contact
Calculation of press size will be done
Feintool will be contact
Conductor and Wedges Insulation:
Experts form CERN has been contacted (they are working on some figures)
Impregnation:
CTD-101K will be used
Price will be required
Confirmation regarding resin volume needed (25% of coil volume) has been requested to the 927 workshop (Nicolas Bourcey) 11

12. Status of the analytical study
Ground insulation: price for Kapton HN 125µm has been required
(500 km length/ 250 mm width)
Rough cost estimation for 127µm film x250 mm width: 10,31€/ m
866€/magnet as 6 layers of polymide are foreseen.
Aluminum shell:
Raw Material: Al alloy
Outer diameter: 820mm
Thickness: 100 mm
Maximum length?
Extrusion press for this size available ?
Laurent Deparis will be contacted. 12