1. SLAC - B (Waveguide Assembly) Final Project Report Eric Coblin Clay Fenstermaker Greg McCandless Eric Schmidt Coach: Vikash GoyalLiaison: Jeff Rifkin

2. Agenda 217A-Product Definition 217B-Product Specification Concept Development Design Recommendations Scorecard Implementation Process Competitive Analysis Questions

3. 217A-Product Definition –Understand the project CVCA Value Graph Function-Structure Mapping Product Definition Assessment Checklist –Quantify the Understanding QFD Cost-Worth Design for Assembly Design for Variety Design for Environment FMEA

5. Waveguide Accelerate Particles Guide Waves Hold Vacuum Run Physics Experiments Learn about the components of atoms Transfer Energy Manufacture Electronics components Have Fun? Run Computer Model EfficientReliableSafe Serviceable Easy to Install Wall Thickness Vacuum Capacity Cleanliness (particulate levels) LengthWeight TubingJoints Hardware Pumps Surface Roughness/ Conductivity WHAT HOW WHY Waveguide Value Graph

14. 217B-Product Specification –Generate Concepts Morphological Analysis Brainstorm Pugh Analysis –Evaluate Options Design of Experiments Poka Yoke-Mistake proofing Motorola Six Sigma Design for Ergonomics Scorecarding Cost Modeling (competitive analysis)

15. Morphological Analysis

16. Design Recommendations Tube Material –Alternatives –Selection Tube Geometry/Parameters Joint Design Tube Segment Length Cleaning

17. Tube Material Alternatives Copper –Low Electrical Resistivity (1.7 x10 -6 Ohm-cm) –Good Outgassing Properties (1 x 10 -13 Torr-l/s/cm 2 ) –Can be Cusil-welded to Stainless Steel –Traditional Choice (Class 1 Used for NLCTA) Class 1 used; could consider Class 2 because no oven braze) –Dense & Expensive Composite Coated Steel –Steel is cheap (but not stainless) –Coating is expensive & not 100% coverage.

18. Tube Material Selected 6061-T6 Aluminum –Good Electrical Conductivity (~51% less than Cu) Can be made up for with larger diameter –Comparable Outgassing to Cu. (1 x 10 -13 Torr-l/s/cm 2 ) –Slightly more strength, less than 1/3 density of Cu Aids in Handling –Approximately ½ cost per lb. than Cu –Cannot be easily joined to Stainless Steel Flanges, but Stainless Steel Flanges no longer required due to less stringent vacuum requirement. (10 -7 Torr)

19. Tube Geometry/Parameters Nominal Thickness: 0.125” –Wrench Drop Test – Pressure Deformation (.0002”) – Electrical Conductivity – Stiffness Nominal ID: 5.1” (vs. 4.75” Cu) –Matches power loss of baseline Cu tube. –Improves fluidic conductivity, C (  D 3 ), which offsets increased outgassing surface area, B (  D 2 ), so reduces spacing required between pumps. Vacuum Pump P0P0 PLPL P0P0 PLPL P0P0 LLLL LPLP LPLP

20. Tube Geometry/Parameters (cont.) Other Tolerances: Taguchi! (at NLCTA) –Also gives opportunity to try Al. SLAC NLCTA SpecStandard ExtrusionStandard Drawn Circularity (Deviation from mean diameter) +/- 0.005" +/- 0.050"+/- 0.016" Surface Finish 32 microinch RMS 0.003" max0.005" max Straightness.010" per 24" Thickness+/- 0.010"+/- 0.0125"+/- 0.006" Dimensions for 5.1" ID tubing 1 Taguchi L 4 Array 1 Standards per the Aluminum Association, Inc.

21. Joint Design “Quick Flange” w/o-ring –Off the shelf –Precisely Locates –Rated to 10 -7 Torr vacuum Up to 10 -9 w/viton & bake-out or perhaps metal o-rings –One Fastener –Tolerates Radiation 1 x 10 5 rad/10 yr = ~800 yr. life Form Flange ends into Al tube –Minimize risk w/proven geometry –Minimize cost w/integration

22. Tubes: Make vs. Buy If made on-sight, could enable “infinite” length, but distance between pumps & handling reasons make this impractical. Want to outsource 1 when –There is a resource limitation. –The requirements are temporary. –There is a push to adopt the best practices from experts in the given field. –There is a drive to reduce time to market. –There is a drive to improve financial performance. Nearly all apply! 1 Per Carol Nast, outsourcing expert in medical devices

23. Tube Segment Length 40 ft. long sections –Max Shippable by standard means –Manufacturable –96.2 lb. per segment- easy to handle –Strength: 1.5 g bump = ~26% of yield- OK!

24. Cleaning Flow Cleaning Agents through ID rather than bathe tubes. –Only uses expensive cleaning agents on ID where needed. –Minimizes Evaporative Losses –Ensures even cleaning Chemical Tank Pump FLOW Sealed ends

25. Scorecard Project Objective: Project Approval Objective Measures: –Cost –Performance (Efficiency, Reliability) Control Factors: –Tube specifications –Joint type Noise Factors: –Variability in manufacturing process –Interaction with other components (radiation, heat) Transfer Function: –To be determined by Taguchi DOE & cost models

26. Implementation Process 12.2 meters AluminumDrill holeExtrude Post-Draw Form & Machine PlugEnds Ship segmentsClean Segments 12.2 meters Fill w/Nitrogen & plug ends,Join segments in tunnel, Transport to tunnelPerform QA 12.2 meters AluminumDrill holeExtrude Post-Draw Form & Machine PlugEnds Ship segmentsClean Segments 12.2 meters Fill w/Nitrogen & plug ends,Join segments in tunnel, Transport to tunnelPerform QA

27. Implementation Process Extrusion Drawing

28. Competitive Analysis Alternatives designed for same performance Main differentiator is Cost

29. Cost Differentiators Material Choice Joint Choice

30. Cost Differentiators Plating and Cleaning

31. Summary of Cost Improvements 45% Savings!

32. Risks True Vacuum Requirements Reliability of Aluminum Packaging Requirements of Aluminum Pump Cost vs. Seal Savings Waveguide Assembly and Service

33. Questions?