LARP magnet R&D program Giorgio Ambrosio TD/MSD

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LARP magnet R&D program

Giorgio AmbrosioTD/MSD

FNAL Annual Program ReviewSeptember 07

OUTLINE

• LARP goals• FNAL contribution to LARP• FNAL core-program support to LARP

September 26, 2007 2

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G. Ambrosio - LARP magnet R&D program

LARP goals “ The US LHC Accelerator Research Program enables U.S.

accelerator specialists to take an active and important role in the LHC accelerator during its commissioning and operations, (…) and to be a major collaborator in LHC performance upgrades” (mission statement)

Form FY08 Org Chart

LARP magnet R&D (FNAL, BNL, LBNL)• From start to FY07: focus on R&D• From FY08: focus on “projectized” tasks


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LARP 2009 Milestone

LARP has a very challenging milestone at the end of 2009

“Demonstrate that Nb3Sn magnets are a viable choice for an LHC IR upgrade”

Technological Quadrupoles (TQ) for performance reproducibility

1 m long, 90 mm aperture, Gnom > 200 T/m, Bcoil > 12 T

Long Racetracks and quadrupoles (LQ) addressing long magnet issues

LQs have same features of TQs 4 m long

High gradient quadrupoles (HQ) to explore performance limits

1 m long, 90+ mm aperture, Gnom > 250 T/m, Bcoil > 15 T

Milestone set in agreement with CERN


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FNAL contribution

“Demonstrate that Nb3Sn magnets are a viable choice for an LHC IR upgrade”

Technological Quadrupoles (TQ) for performance reproducibility

1 m long, 90 mm aperture, Gnom > 200 T/m, Bcoil > 12 T

Long Racetracks and quadrupoles (LQ) addressing long magnet issues

LQs have same features of TQs 4 m long

High gradient quadrupoles (HQ) to explore performance limits

1 m long, 90+ mm aperture, Gnom > 250 T/m, Bcoil > 15 T

FNAL: Host lab for TQC magnets

FNAL: TQS coil winding & curingTQS magnet test at 1.9K

FNAL: L2 coordination

FNAL: Design Study L2 coordination

FNAL: LQ coil development and fabrication, LQ design with alignment, LQ test at 1.9KFNAL: Design

Study task leader

FNAL: Contribution to all WGsStrand study task leaderMagnet test coordination leaderOnly lab for 1.9K magnet test

Long Mirror (LM) addressing long coil & magnet issues

2 and 4 m long, single cos coil, Bcoil ~ 11 T

FNAL core program taskIn support of LARP


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Technological Quadrupoles Two mechanical designs are under developmentSame coils / Aperture = 90 mm / Gradient > 200 T/m @ 4.2K

2 layers

FillerKeys

4 pads

Bladder

Yoke

Aluminum shell

TQC: using collarsCollar laminations from LHC-IR quads1st time applied to Nb3Sn coils

TQS: using Al-shellPre-loaded by bladders and keys1st time applied to shell-type coils

YokeGap

Collar-YokePreloadShim

ControlSpacer

Skin

Collar

YokeCollaringKey

Inner poleOuter polepiece

Coil MidplaneShim

FNAL: concept, design, development, coils fabric., assembly & test

FNAL: coils fabric, test at 1.9K


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TQ Coil Fabrication

• TQ coil fabrication techn. is mostly based on FNAL technology

Water Jet Machined Part

Ceramic binder for insulation, water-jet technology for end-parts, reaction procedure with azimuthal and pole gaps, segmented tooling with “gentle-transfer” procedure, splice design and procedure

• All coils (29) for the 1st magnet series have been wound and cured at FNAL, reacted and impregnated at LBNL;

• TQC02 coils completely fabr. at FNAL


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TQC Development

• New FEM analysis with Nb3Sn plasticity (1st in the field)

• Four mechanical models have been assembled and tested in order to develop collaring procedure for Nb3Sn coils

Stress in different longitudinal sections during keys insertion: uniform within +/- 5 MPa

0

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0 0.001 0.002 0.003 0.004 0.005 0.006

Strain

Str

ess,

MP

a

Elasticity

GPa

Plasticity

free

5 m

m (

blo

ck 1

)

5 m

m (

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ck 2

)

5 m

m (

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ck 3

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5 m

m (

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ck 4

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7 m

m (

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ck 1

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7 m

m (

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ck 2

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7 m

m (

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ck 3

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7 m

m (

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9 m

m (

blo

ck 1

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9 m

m (

blo

ck 2

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9 m

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9 m

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9.3

mm

all

blo

cks

-80

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-10

0

Key travel

Stress strain plot showing plastic-elastic behavior of coil samples


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TQCs Status and Plans

TQC01:– 70% at 4.5K– 85% at 1.9K – Damage during test

TQC01b:Re-assembly with 2 TQS

coils– 85% ssl at 4.5 K– 89% at 1.9 K– Reached G = 200 T/m

Constant improvement in understanding and process control

TQE02:TQC with TQS02 coils– To be tested early Oct

TQC01b training history

TQS02 (with RRP 54/61 coils) assembled at LBNL, tested at FNAL, reached ~215 T/m at 4.5 K

TQC01b Quench Training at 4.5K and 1.9K

50006000700080009000

10000110001200013000

0 20 40 60 80

Quench #

Cu

rre

nt (A

)Coil 07

Coil 08

Coil 10

Coil 12

4.5K 1.9K

13400 A

12400 A4.5K

TQC01b Quench Training at 4.5K and 1.9K

50006000700080009000

10000110001200013000

0 20 40 60 80

Quench #

Cu

rre

nt (A

)Coil 07

Coil 08

Coil 10

Coil 12

4.5K 1.9K

13400 A

12400 A4.5K


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Plan for Length Scale-Up

LENGTH SCALE-UP CHALLENGE: No Nb3Sn accelerator magnet longer than 1m has ever been builtLARP should make a successful 4m long quadrupole by end of 09

FNAL Long MirrorsFNAL

LARP Long QuadrupolesFNAL, LBNL, BNL

LARP LQ Design Study

LARP Long RacetracksBNL, LBNL, FNAL

2006

2007

2008

2009

LARP TQs


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LARP Long Racetrack

The goals of the Long Racetrack (LR) are: to fabricate and test long Nb3Sn racetrack coils Performed at BNLto test an Al-shell-based supporting structure Developed at

LBNL(preloaded using bladders and keys)

FNAL contributions:L2 coordination of Supporting R&D (G. Ambrosio)FNAL scientists and engineers are part of LR working groupTechnology transfer from the LR to the LQ, Insulation development, Practice coil insulation

Coil layout: two flat double-layer racetrack coilsTechnology developed at LBNL, modified at FNAL, successfully transferred to BNL

From 0.3 m to 3.6 m

Results:

- Iq> 90% ssl

- Shell should ..be segmented


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FNAL Long Mirror• FNAL “Mirror magnet” is a cos-theta dipole where a coil is

substituted by iron blocks• Successful 2m mirror magnet (same performance of 1m model)• 4m mirror magnet will be tested in November

Front view of mirror magnet

ADVANTAGES - Larger probability of success of the LQ by:Several features complementary to LRs Diversity & Risk mitigation

- conductor, keystoned cable, insulation, coil shape, use of wedges, mechanical structure,Start as soon as possible development and qualification of tooling and infrastructure for long magnets at FNAL (New 6-m long oven, …)

LM02 quenchhistory at 4.5Kcompared with 1m model

15000

16000

17000

18000

19000

20000

21000

22000

0 5 10 15 20 25 30

Quench number

Qu

ench

cu

rren

t, A

LM01

HFDM03

SSL


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LQ plans

Present plan (still under development):• LQ project leadership – FNAL• LQ coil winding & curing – FNAL• LQ coil reaction & impregnation – FNAL &

BNL• LQ support structure with shell – LBNL & BNL• LQ support structure with coil alignment –

FNAL• LQ quench protection – FNAL & LBNL & BNL• LQ magnet tests – FNAL & BNL


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Other parts of LARP magnet R&D

• FNAL has a major role in Design Studies: – LARP L2 coordinator (Zlobin) – LARP Long Quadrupole DS task leader (Ambrosio)– Tasks: High Grad Quad, IR Study, Radiation deposition,

Cryogenics, Heat transfer

• … also in Material R&D:– Strand R&D task leader (Barzi)– Tests of strands and cables in

different conditions (pressure, field, temperatures)

• … also in Magnet testing:– LARP magnet integration

coordination– Only LARP lab with 1.9K capability– Developed low-noise high-

frequency spike detection system

Tests of SQ02 (small quadrupole with racetrack coils) fabricated at LBNL


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Budget and Resources

FY07 resources: 5 physicists 8 engineers 2 designers 9 technicians + support. staff (~21 FTEs)

• The LARP budget is almost constant (+10%)• In FY08 the Core Program budget is decreasing because the Long Mirror is

phasing down ( low M&S, lower SWF); some FTEs to other magnet programs • In FY09 the Core Program budget is back to $4.6M in preparation for IRUP

• The continuity of the core program allows for continued growth in expertise and infrastructure we are able to respond quickly to the needs of the field

FY06 FY07 FY08 FY09

LARP magnet R&D

$1.9M

$1.9M

$2.0M

$2.1M

FNAL magnet R&D

$4.7M

$4.7M

$3.6M

$4.6M

Budget with G&A


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Conclusions

• LARP is starting an exciting and challenging phase– Goal: demonstrate that Nb3Sn magnets are viable

option for an LHC IR upgrade

• FNAL is supporting all LARP goals – With key contributions in all tasks

• technical and managerial level

– With unique contributions in several tasks• such as 1.9K magnet test capability, long coil winding

and curing, coil collaring, conductor characterization, …

– Has achieved important results (TQC01b)

• FNAL is providing further support by core-program – Long Mirror magnets, Conductor R&D


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LARP Mission Statement

The US LHC Accelerator Research Program enables U.S. accelerator specialists to take an active and important role in the LHC accelerator during its commissioning and operations, and to be a major collaborator in LHC performance upgrades. In particular, LARP will support U.S. institutions in LHC commissioning activities and accelerator science, accelerator instrumentation and diagnostics, and superconducting magnet R&D to help bring the LHC on and up to luminosity quickly, to help establish robust operation, and to improve and upgrade LHC performance. Furthermore, the work we do will be at the technological frontier and will thereby improve the capabilities of the U.S. accelerator community in accelerator science and technology to more effectively operate our domestic accelerators and to position the U.S. to be able to lead in the development of the next generation of high-energy colliders.


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LARP FY07 Org Chart

FY07 Org Chart


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LARP FY08 Org Chart

FY08 Org Chart


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SC Magnet R&D at Fermilab

• Fermilab has a long (~30 years) and successful history of SC accelerator magnet R&D– Tevatron, Low Beta Quads, SSC dipoles, VLHC superferric

transmission-line, LHC IR Quads, HFM dipoles

• This is because SC magnets are an enabling technology for high energy accelerators

“The tremendous accomplishments of these last two years confirm the broad strength of the group”

“In many areas basic elements of the Fermilab program, such as tests of material, establishment of fabrication processes, design and fabrication of tooling and fixtures, are essential to LARP success”

Jan 06 - High Field Magnet review (L. Rossi, chair)

LARP magnet R&D program Giorgio Ambrosio TD/MSD

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