1. International Workshop on Linear Colliders 2010 Design and fabrication update on PSI/Trieste X-band phase- space rotator structure Dmitry Gudkov 21-OCT-2010 WG 4 «Main Linac and NC RF»

2. Contents 2 Aim of Engineering Design Engineering Design Overview Mechanical Design of Copper Disks and Couplers Accelerating Structure Assembly Sequence Cooling System Wake field monitor Feedthrough Tuning System Fabrication strategy

3. 73 Cells 2 Couplers 2 Regions for monitoring wakefields Aim of Engineering Design The aim of engineering design of the structure is to transfer the RF geometry into real hardware device which can be produced with existing technological methods of metal working and assembly. The European FEL projects FERMI@ELETTRA and PSI-XFEL plan to employ an X-band structure to compensate nonlinearities in the longitudinal phase space in order to improve bunch compression. * RF-design done by R. Zennaro, M. Dehler and colleagues from PSI 3

4. Engineering Design Overview 4 - The accelerating structure consists of two coupler subassemblies, 73 disks and includes a wakefield monitor and diagnostic waveguides; - The engineering study includes the external cooling system, consisting of two parallel cooling circuits; - RF tuning system, which allows phase advance tuning of the cell by deforming the outer wall; - The engineering solution for the installation and sealing of the wake field monitor feed- through devices that are integrated in the accelerating structure are presented.

5. Mechanical Design of Copper Disks and Couplers 5 - The accelerating structure body consists of a stack of thick cylindrical copper disks, which are machined following the RF design of the cavity geometry. - For the final RF frequency tuning, the disks are equipped with four radial holes. - Each special wakefield monitor disk incorporates four coupling holes and is also equipped with tuning holes. Wakefield monitor waveguide Radial tuning holes Hole for feedthrough installation

6. Mechanical Design of Copper Disks and Couplers 6 Cell shape accuracy 0.004 mm Flatness accuracy 0.002 mm Cell shape roughness Ra 0.025

7. Standard Disk Mechanical Design of Copper Disks and Couplers 7 WFM Disk Type 1 WFM Disk Type 2 WFM Disk Type 3 WFM Disk Type 4 WFM Disk Type 5 WFM Disk Type 6 Interface Disk (Brazing) Coupler Body

8. Accelerating Structure Assembly Sequence 8 1.Bonding of 3 stacks containing 24..25 disks each -Each stack includes one disks with slots for the next operation of brazing. -Slots are used for insertion of brazing alloy PHOTO: S. LEBET.

9. Accelerating Structure Assembly Sequence 9 Bonding of 5 test disks Cut Metallographical observation....shows that grains are crossing the joining plane Load pressure 0.28 MPa

10. Accelerating Structure Assembly Sequence 10 2. Brazing of couplers x 2 x 4 3. Brazing of waveguides and RF flanges together 4. Machining of pockets for insertion of waveguides on the next brazing operation 5. Brazing of coupler body and waveguides together

11. Accelerating Structure Assembly Sequence 11 7. Brazing of inserts X 8 8. Brazing of tuning studs X 104 Alignment of stacks using ceramic pins 6. Brazing of 3 stacks with couplers. Angular alignment: Diamond stylus reference line

12. Accelerating Structure Assembly Sequence, Cooling System 12 9. Brazing of cooling blocks (Cu) Flexible hoses WITZENMANN Standard fittings LEGRIS 10. Connection of fittings and hoses - Power dissipation in the structure of about 0.3 kW; - Two parallel cooling circuits; - 8 cooling blocks each of 394 mm long; - Brazed directly onto the accelerating structure body; - Standard water connectors.

13. Accelerating Structure Assembly Sequence, Wake field monitor Feedthrough 13 Custom design of feedthrough (Produced by Orient Microwave) Copper adapter flange Special connector Electron-beam welding TEST 11.Installation and sealing of Wake field monitor Feedthrough - Based on standard feed-through - Special end of connector - Specially designed adapter from the standard feed-through to the accelerating structure body - The adapter is laser welded to the feed-through - Final, vacuum tight connection of the feed-through assembly is made by electron beam welding

14. Tuning System 14 PUSH-PULL Guide Hammer - Integrated tuning system; - Push-Pull Principle; - 4 tuning studs inside each cell.

15. Fabrication strategy 15 Prototype phase: Successfully finished Series production phase:

16. The End 16 Thanks to: Micha Dehler Germana Riddone Alexandre Samoshkin Riccardo Zennaro Serge Lebet Said Atieh Vincent Sibue Alexey Grudiev REFERENCES [1] M. Dehler, et al, “X-Band RF Structure with Integrated Alignment Monitors” Phys. Rev. ST Accel. Beams 12, 062001 (2009).M. Dehler [2] J.P. Delahaye et al, “Towards CLIC feasibility”, paper presented at IPAC2010. [3] CATIA ® Version 5.16 © Dassault Systemes 1994-2008. [4] http://www.orient-microwave.com/http://www.orient-microwave.com/ [5] Juwen W. Wang et al. “Fabrication Technologies of the High Gradient Accelerator Structures at 100MV/m Range”, paper presented at IPAC2010.