1. ILC R&D at Fermilab Robert Kephart

2. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review2 Outline Fermilab ILC Goals Fermilab’s role in the GDE & the ILC machine Design Main Linac design –Accelerator physics –Main Linac components (Cryomodule, RF components) SCRF Cavity & Cryomodule R&D –Cavity R&D –3.9 GHz and 1.3 GHz Collaboration with DESY –ILC Cryomodule Design RF activities ( Modulators, Klystrons, LLRF & Controls) SCRF infrastructure –FNAL/ANL joint facility for cavity BCP and EP –Cryomodule assembly Facility –ILC test facilities (ILCTA) ILC Civil and Site Development Industrialization Funding Conclusion

3. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review3 Goals of Fermilab’s ILC R&D The overarching goal of Fermilab’s ILC R&D program is to establish credentials in machine design and SCRF technology such that FNAL is the preferred international site to host the ILC. As part of the Global Design Effort (GDE) our goal is to help design the machine, estimate the cost, and gain international support. Fermilab ILC R&D activities: –ILC Machine Design –Development of SCRF technology & infrastructure –Conventional Facility & Site Studies for a US ILC site –Industrialization & Cost Reduction –ILC Physics, Detector Design, and Detector R&D

4. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review4 Fermilab’s Role in the GDE GDE goal = complete the Reference Design Report (RDR) and a cost estimate by the end 2006  established RDR organization Design & Cost Board (coordinates machine design) –Responsible for producing the RDR and the cost estimate –9 members ( 3/region) + Chairman –P Garbincius ( FNAL) = chair, R. Kephart (FNAL) member Change Control Board (ILC baseline configuration control) –9 member board (3/region), N Toge = Chairman –S. Mishra (FNAL) is one of 3 U.S. Members ILC Machine “Area” Leaders (typically 3 Ldrs 1/region) –Civil and Site: Vic Kuchler (FNAL) = Americas Ldr –Main Linac Design: N. Solyak (FNAL) = 1 of 2 Americas Ldrs –Cryomodule: H. Carter (FNAL) = Americas Ldr –Cryogenics system: T. Peterson (FNAL) = Americas Ldr –Magnet systems: J. Tompkins (FNAL) = Americas Ldr –Communications: E. Clements (FNAL) = Americas Ldr FNAL is playing a major role in the GDE & ILC machine design

5. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review5 ILC Machine Design Fermilab has focused its R&D efforts on the ILC Main Linacs. Main Linac activities: –Accelerator physics design –Demonstrate feasibility of all Main Linac technical components –Engineering design of ML technical systems –Estimates of the ML cost & methods for cost reduction –U.S. Industrialization of high volume ML components Other R&D ( smaller efforts) –Design studies of the ILC Damping Rings –Working on the Machine-Detector Interface –Physics studies & Detector R&D Civil and Site Development activities: –Civil engineering of machine enclosures –With the GDE, develop a matrix for comparing possible ILC sites –Study U.S. sites on or near the Fermilab site

6. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review6 Accelerator physics: –Main Linac optics studies –End-to-end simulation of the machine –Study emittance preservation and vibration issues –RF timing and control issues Engineering Design of Main Linac components –Fermilab has been asked to supply lots of engineering in FY06 in support of the Main Linac design for the RDR –Cryomodule Development (incl. high gradient cavities!) –Cryogenic & RF system Design –LLRF & control systems design –Design of linac auxilary systems In April of 2006 FNAL had 120 FTE working on ILC R&D or on developing lab SCRF expertise Main Linac Design

7. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review7 SCRF Cavity R&D Our goal is to rapidly advance the intellectual understanding of SCRF surface physics and establish process controls to reliably achieve high gradient ( 35 MV/M) SCRF cavity operation Approach: Establish a “tight loop” processing and test infrastructure in the U.S. Tight loop elements: –Cavity fabrication improvements ( e.g. large grain Nb) –BCP & Electro-polish facilities –High purity water and High pressure rinse –Vertical test facilities –SCRF experts & materials program to interpret results SCRF materials program =FNAL,UW,NW,Cornell,TJNL,MSU, etc

8. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review8 ILC 1.3 GHz Cavities @ FNAL Industrial fabrication of cavities, some in U.S. Industry Two Single/large Crystal cavities under development with TJNL BCP and vertical testing at Cornell (25 MV/m) (17 MV/m 1 st try) Next … EP and vertical testing at TJNL. ( 35 MV/m) Joint BCP/EP facility being developed ANL (2007) High Power Horizontal test facilities @ FNAL (2006) Vertical test facility @ FNAL (2007) More later on these facilities 4 cavities received from ACCEL 4 cavities on order at AES 2 cavities on order at TJNL BCP and Vert Test at Cornell

9. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review9 DESY Collaboration Fermilab and DESY have collaborated on advanced accelerator R&D for many years As members of the TESLA collaboration: –FNAL & DESY collaborated to build both TTF & the Fermilab NICADD Photo-Injector Lab (FNPL) at A0 –Currently FNAL is building a 3.9 GHz 3 rd Harmonic module for the TTF @ DESY (doubles light output of the VUV-FEL) Status of the 3.9 GHz effort –3.9 GHz cryomodule design is complete –Uses four 9 cell 3.9 GHz cavities ( 2 of 6 total are now welded) –BCP processing at joint ANL/FNAL facility in FY06 –Vertical test @ A0, Horizontal test in ILCTA_MDB Serving as a pilot program for much of our ILC SCRF infrastructure (processing, vertical and horizontal test, cryomodule assembly, etc.) Expect to deliver the 3.9 GHz module to DESY in early 2007

10. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review10 DESY Collaboration 3.9 GHz 9 cell 3.9 GHz cavity

11. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review11 DESY Collaboration DESY and INFN will supply Fermilab with all the parts for one 1.3 GHz (type 3) TESLA cryomodule –DESY will send us 8 TESLA 9 cell cavities –Vertically tested, dressed, & horizontally tested @DESY –Goal is to qualify them to 28 MV/M –DESY will also supply cold mass parts –Expect all parts at FNAL early in FY07 Will be the 1st ILC type cryomodule built in the U.S. Plan to assemble it by summer of 2007 Then… test it at Fermilab later that year

12. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review12 ILC Cryomodule ILC Cryomodule Design –Collaborative effort on the next generation ILC cryomodule 1 st ILC Cryomodule (2006-07) –Assemble a TESLA TTF type III cryomodule from the “kit” of part provided by DESY, cavities fully tested. 2 nd Cryomodule (2007-08) –Also TTF type III cryomodule –Uses cavities that are processed and tested in the US Cavities: Accel(4), AES(4), TJNL(2) Cryostat and cold mass from Zannon in Europe –BCP processing at JLAB & Cornell –Electropolish at JLAB and perhaps ANL/FNAL joint facility –Vertical test (bare) at Cornell & JLAB –Horizontal test (high power) at FNAL ILCTA_MDB

13. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review13 ILC Cryomodule 3 rd -4 th Cryomodules (2008-09) –1 st type IV cryomodules built anywhere –Begin industrial production of components –Assembly and test at Fermilab 5 th -6 th Cryomodules (2010) –Transfer knowledge gained to Industry for ILC cryomodule mass production 2006-2010: Develop, build & test basic building blocks of the Main Linac –Cryomodules (including cavities, couplers, instrumentation, etc) –RF systems ( modulators, klystrons, LLRF) –Cryogenic system design Evaluate main linac cost and reliability issues

14. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review14 Cryomodule ILC cryomodules are complex objects TTF cryomodules (type III) need to evolve for ILC FNAL is collaborating with DESY, INFN, KEK, CERN, JLAB, SLAC, etc. on the design of the next generation ILC cryomodule (Type IV) DESY TTF ILC cryomodule

15. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review15 Main Coupler & Tuner R&D TESLA Blade-Tuner Fermilab is also working on controlling Lorentz detuning via Piezoelectric tuners in a feed-forward system TESLA Main Coupler 1.3 GHz, pulsed operation Two windows, adjustable 2K (4K) heat load 0.06 (0.5) W Main Couplers and tuners are complex FNAL plans R&D aimed at cost reduction

16. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review16 ILC RF Systems R&D Modulator R&D –10 Modulators built b ased on Fermilab design –3 by FNAL and 7 by industry –In operation ~10 yrs @ DESY and FNPL –2 new Modulators will be finished in FY06 –1 = PD, other = ILC, collaborating with SLAC Klystrons –Design improvements are needed to reach reliable long-term operation at 10 MW peak / 150 kW average power. –Also need to develop U.S. vendors –SLAC will supply a new 10 MW klystron LLRF R&D in collab Penn, DESY, INFN, etc. FNPL Modulator 10 MW Thales Klystron

17. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review17 ILC RF Systems R&D Overall objective is to assemble one, then two ILC RF units in New Muon building ( ILCTA_NM) 1 st by about 2009, 2 nd a year or so later –Two x 3 Cryomodules –Two Modulators –Two 10 MW Klystrons –Waveguide and RF distribution components –LLRF & controls –Move FNPL photo injector to provide electron beams Other RF tasks –3.9 GHz RF power and LLRF for tests –Small RF systems for Vertical & Horizontal test facilities –Industrialization of RF components (more in a minute)

18. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review18 Following the technology choice in Aug 04 FNAL launched a major program to develop the extensive SCRF infrastructure required for ILC –ILC/GDE specific R&D tasks described in an MOU –FNAL is also spending “lab” operating funds on this The required infrastructure is complex –It takes time to develop –It takes time to train personnel to achieve cavities with high operating gradients –It is expensive! DESY spent >125 M euro M&S on TTF and the associated infrastructure Costs are “front loaded” but our funding is not Our ability to make progress is funding limited SCRF infrastructure

19. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review19 SCRF Infrastructure High gradient cavities require extensive infrastructure Bare cavities –Fabrication facilities ( e.g. Electron beam welders) –Buffered Chemical Polish facilities (BCP) –Electro-polish facilities (EP) –Ultra clean H 2 0 & High Pressure Rinse systems –Vertical Test facilities ( Cryogenics + low power RF) Cavity Dressing Facilities ( cryostat, tuner, coupler) –Class 100 clean room –Horizontal cavity & Coupler test facility ( RF pulsed power) String Assembly Facilities –Large class 100 clean rooms, Large fixtures –Class 10 enclosures for cavity inner connects Cryo-module test facilities –Cryogenics, pulsed RF power, LLRF, controls, shielding, etc. –Beam tests  electron source (e.g. FNPL Photo-injector) FNAL and U.S. collaborators are building this  $$$$$

20. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review20 TJNL e-beam welding Chemistry TJNL Electro polish Horizontal Test of Dressed Cavity @ DESY Examples: SCRF infrastructure Cryomodule Test at DESY TTF

21. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review21 The inter-cavity connection is done in class 10 cleanroom Examples: Cryomodule Assembly Assembly of a cavity string in a Class 100 clean room at DESY Cryomodule Assemby at DESY Lots of new specialized SCRF infrastructure needed for ILC!

22. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review22 Building U.S. SCRF infrastructure Existing U.S. facilities at Cornell, TJNL, and ANL are being upgraded to process the 1.3 GHz ILC cavities but not sufficient A new FNAL/ANL BCP facility built at ANL (operational late 2006) An Electro-polishing facility is being designed by the ILC Collaboration A prototype will be built at ANL/Fermilab Cavity Processing Facility at ANL.

23. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review23 FNAL SCRF Infrastructure CAF-MP9 Large Class-100 clean room Installed & Passed certification A Cryomodule Assembly Facility (CAF) is being built in (MP9) Vertically tested cavities will be dressed (He vessel, coupler, etc) in smaller clean rooms prior to horizontal test Horizontally tested cavities assembled into a string in large clean room before final Cryo-module assembly takes place Parts for new Cryomodule Assembly fixture in IB4 Plan = expand CAF into Industrial Center Bldg after LHC quads

24. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review24 ILC Test Areas (ILCTA) SCRF test facilities are needed to carryout the ILC program Vertical Test (bare cavities) IB1 –IB1 has 60 W @ 1.8 K now –Ordered dewar, civil in progress Horizontal Test (dressed cavities) –IB1 & Meson Bldg (PD) –Meson will have 60 W @ 1.8 K soon Cryomodule test facility –Contract to remove CCM –installing cryogenics –Photo injector moves  e beam –Power 1 st cryomodule in 2007 RF Power & Cryogenics  These are Big expensive facilities ! Industrial Building 1 New Muon Lab

25. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review25 Civil and Site Development Goal: Determine the best possible site for an ILC in Illinois With the GDE we are developing the ILC Civil Design –Tunnel Design ( diameter, # shafts, laser-straight vs curved Site specific machine and Civil design will start in FY07 –Geological, environmental, community impact studies not to scale ~30 km x2 R = 955m E = 5 GeV ML ~10km (G = 31.5MV/m)  3.2 m  5.5 m  4.5 m not to scale RDR FNAL site

26. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review26 Industrialization The principle goal of ILC industrialization is to establish in US industry the capability and infrastructure to mass produce the components to build the ILC Another important goal is cost reduction Cryomodules (2000 required for 500 GeV of linac) SCRF Cavities: (16,000) –Reliably achieve > 35 MV/m and Q ~1x10 10 RF couplers and Cavity Tuners (16,000 each) RF Components –~ 650 klystrons ( 1.3 GHz, 10 MW, 1.5 ms, 5 Hz) –~ 650 modulators –Waveguide, circulators, host of other RF and vacuum components…

27. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review27 Industrialization Large Cryogenic systems (~ 40 KW at 1.8 K) Detectors, instrumentation, etc… Civil construction –A huge job ( currently estimated @ 40% of the ILC cost) In FY06 the GDE plans Industrial cost estimates –Limited in scope ( available funding is small) US industrialization for ILC is just beginning –FNAL helped create an Industrial Forum in 2005 –Industrial involvement in cost estimates has started –Need industrial studies aimed at cost reduction –Need industry to build things ! Our ability to engage U.S. industry is limited by the available funding Hope is that FY07 funding will allow a sensible start

28. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review28 Systems Tests It is Fermilab’s opinion that a significant systems test will be required in advance of ILC construction to verify: –Technical performance of critical/cost driving components –Systems integration –Vendor performance –Reliability of cost estimate Should include ~1% of final cryomodule count, produced by vendors in a pre-production run –Plan is to assemble into ~ 5 GeV electron linac –Mount in a near surface twin tunnel ILC mock up –Could include a demonstration damping ring in Tev Tunnel We propose to host this facility at Fermilab Believe the correct approach is to develop requirements first, then evaluate possible facilities. –Discussion with the GDE are in progress

29. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review29 ILC and SCRF Resources FY06: FNAL program was scaled back to fit budget. FY07 represents Fermilab desires (actually->186 FTE) Bid-to-host funds mostly go to outside A&E firms Numbers are direct  no overhead

30. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review30 Conclusions Fermilab has a large and growing ILC R&D effort Our prime objective is to achieve technical excellence in the Main Linac systems and to position ourselves to be a strong candidate to host the ILC We work closely with international partners in the GDE on the machine design –Main Linac ( accelerator physics, simulation ) –Civil & Site studies –Accelerator systems( cryogenics, RF, controls, etc) –Small efforts on electron source, damping rings We are building an extensive SCRF infrastructure and developing expertise in support of these goals –High gradient cavities (design, fabrication, BCP, EP ) –Cryomodule Design & Assemby ( CAF) –Cavity test facilities ( horizontal and vertical) –Cryomodule Test facilities ( ILCTA including beam tests ) Our progress is limited by the available funding