1. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 SC RF cavity technology: the possibility of mass scale production, a global review Remarkable production experience exists for elliptical type cavities made from solid Niobium ( around 500 units) –Mainly by European companies TESLA (20,000) and XFEL (1,000) pushed industrial effort for mass scale production –ILC just starts this effort in USA and Japan This talk gives a global overview on the present state of knowledge about mass scale production and related costs

2. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Technical systems: Cavity / module Overview on costing activities for mass scale production –European costing method Overview industrial methods General comments on industrialization, risk in costing –Short report on American costing method –Short report on Asian costing method Conclusion

3. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Technical systems: Cavity / Modules Elements in cavity / module system –Niobium material –Cavity fabrication Input coupler HOM coupler Tuning system –Cavity treatment –Module assembly

4. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 European Approach to industrial mass production Industrial studies for TESLA (20000 cavities) at 2001 Appendix to TESLA: XFEL part at 2001 –1000 cavities Revised XFEL TDR at 2006 –Corrections for Increased material costs Risk assessment for costs Inflation For ILC: Corrections / modifications to TESLA costs based on findings in XFEL part

5. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 TESLA 500 20000 cavities XFEL TDR 1000 cavities ILC Costing 18000 cavities XFEL Appendix 1000 cavities Industrial Studies European cost approach for mass scale production New industry studies -Module assembly -Coupler fabrication

6. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 European cost / mass production evaluation by Industrial Studies Analyze production of TTF components –Describe present fabrication process –Determine cost drivers, critical procedures –Define core technology, outsourcing possibility Implementation of mass production methods –Evaluate investment of machinery, tooling, roboting –Cost optimize flow of fabrication –Describe layout for “core tech” factory

7. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 European cost / mass production evaluation by Industrial Studies, cont. Complete planning of new “core tech” factory –Determine costs for buildings, investment, man power, ramp up & production & ramp down, overhead, consumables, QC,… –Get bits for outsourced parts –Sum up total cost of component fabrication NO learning curve assumed (e.g. -10% for doubling the production) But assumption: stable production after about 50 cavities, couplers,… –Is verified e.g. by LHC magnet production: assembly time reached stable (and predicted) level after about 40 magnets This cost model is valid because it was developed by experienced companies. Additional studies would require time, money and competent industry.

8. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Components with European Industrial Studies Niobium fabrication, done Cavity fabrication, done Cavity treatment,done Module assembly, done –Revised study is in progress Input coupler fabrication –Study in progress

9. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 500KW electron beam cold hearth furnace

10. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Comments to cost evaluation Nb Material (high purity, RRR 300) –No shortage of raw Nb material (40.000 tons annual production, ILC needs around 500 tons –But limited number of high purity melting facilities Today there are 4 qualified companies, but only one is capable of producing full yield –Marginal savings in mass production (from industrial study) Size of melting furnace is limited But some saving can be realized by –Disc rather than rectangular sheet (scrap can be recovered) –Other material produced ready for fabrication, e.g. flange material But: Latest developments in large/single crystal cavities promise cost reductions The result is robust costing

11. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006

12. Niobium RRR 300 9 cells: compromise between filling factor and trapped modes 1.3 GHz Deepdrawn from sheetsWelding with electron beam Operating temperature 2K TESLA 9-cell Niobium Cavity Proposal is based on proven available technology

13. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Cavity production

14. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Comments to cost evaluation Cavity fabrication –Experienced companies in Europe More than 500 type TESLA cavities have been fabricated so far Fabrication process is well understood and stable Cost drivers: EB welding process (50% total cost) –Cure: reduced pump down time by multiple vacuum chambers welder –Cure: mass production welding tooling Cost saving in large scale production is well understood The result is robust costing

15. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Reduction of fabrication cost 3 vacuum chamber welding machine: –Pump down and cool down in separate chamber –Welding in middle chamber Tooling for welding many parts in one cycle Outsource machining of parts

16. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Production facility

17. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006

18. DESY Electro-polishing machine

19. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Comments to cost evaluation Cavity treatment –Standard treatment is EP, 130°C bake, high pressure water cleaning, clean-room assembly –Technology transfer to industry just started Cost evaluation has some uncertainty Industrial involvement is needed to develop procedures which produce higher performance yield Costing result has risk: –Uncertainty in cavity treatment

20. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Baseline design

21. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Comments to cost evaluation Input coupler –Cost is high, comparable with cavity fabrication !! –Present industrial fabrication around 80 couplers. Industry identified cost savings which were included, e.g. standardized tube sizes –Ongoing industrial study (XFEL) on mass production will deliver a reliable cost number Present costing has some risk –But ongoing industrial study will deliver robust costing

22. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 For the XFEL power couplers, industrialization studies will be performed through “Definition contracts” : Essentially intellectual work (in dialog between the industry and our Lab) :  Define all manufacturing processes (analysis and validation models)  Risk analysis (process, logistics)  Determine cost in series and justify Produce 2 prototypes (to be tested at LAL – Orsay) Particularities 3 contracts will be awarded on the same subject: « Industrial studies » 2 teams will be selected after final evaluation contracts for manufacturing 2 series of 500 XFEL couplers will be awarded without a new call for tenders the 2 contracts may be awarded to a single company

23. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Cavity Preparation; String and Module Assembly

24. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006

25. Cryomodule Assembly Clean room assemblyAssembly outside cleanroom the study shall cover clean room assembly and the assembly outside cleanroom Startpoint: string assembly in cleanroom (all parts are tested and ready for assembly)

26. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Scope The present cryomodule assembly procedures and some aspects of the present design shall be analyzed and questioned with respect to the most cost effective serial production. The key aspects of the study are as follows: 1.2.1 Define the assembly procedure 1.2.1 Analyze cost-reduction and production efficiency measures 1.2.3 Analyze performance improvement measures 1.2.4 Supply a cost estimate for the module production A substantial part of the IS shall be the presence of CONTRACTOR’s experts during the assembly of two prototype cryomodules at DESY. Industrial XFEL-cryomodule design and assembly study Supported by the EUROFEL design study

27. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 American costing method There is fabrication experience in some laboratories from earlier projects American industry was only involved to minor extend A new industrial study on cavity mass production is on the way Costing is based on prototype fabrication and learning curve for mass production

28. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Asian costing method In Japanese culture industry has been involved in early stage in accelerator projects, e.g. Tristan, KEKB Industry is a major driver in EP (electro polishing) and coupler development In house (KEK) cryo-module development is under way Costing is a combination of industrial involvement and learning curve

29. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Summary & Conclusion: Mass scale production of SC accelerator systems Industrial expertise exists in SC cavity and for most of the SC sub-systems ( auxiliaries) European Industry has a world leading position –Japanese industry has specialized expertise –US industry just starts in SC technology SC cavity technology is based on solid Nb material

30. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Perspectives of thin film technology Immediate benefit –Thin Nb film is much cheaper than bulk Nb sheet: A must for large cavities ( at low frequencies) Short term goal –Thin Nb films promise enhanced intrinsic properties (high Q value, no need for magnetic shielding,… Long term goal –Use of new SC compounds with higher critical fields and/or at higher temperatures

31. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006 Strategy Lets combine the enhanced thin film properties with the industrial experties in bulk Nb for the next generation of SC cavity mass production technology

32. D.Proch, Thin film Workshop, Legnaro, Oct. 9-12. 2006

33. Design of the new slow & fast cold tuner CARE JRA-SRF Partner Cooperation between : TUL (Polen), CNRS Orsay, CEA and INFN Mi