5 th clic-ace structure production in laboratories and industries
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5 th CLIC-ACE Structure production in laboratories and industries. G. Riddone, 02/02/2010 (contribution from KEK/SLAC colleagues). Content. Introduction to RF structures and components Fabrication baseline procedure for accelerating structures - PowerPoint PPT PresentationTRANSCRIPT
5th CLIC-ACE
Structure production in laboratories and industries
G. Riddone, 02/02/2010
(contribution from KEK/SLAC colleagues)
1
2
Content
• Introduction to RF structures and components
• Fabrication baseline procedure for accelerating structures
• Application to CERN accelerating structure fabrication
• Fabrication of PETS
• RF structure production capability
• RF structure master schedule
• Present structures (CERN, KEK, SLAC, Elettra, PSI)
• Towards CLIC structures (CDR, TDR)
G. Riddone, 5th CLIC-ACE, 02/02/2010
Introduction
G. Riddone, 5th CLIC-ACE, 02/02/2010 3
TD18#3 at SLAC
TD18#2 at KEK
TD24#2 at CERN (12 GHz)
PETS (12 GHz, TBTS)
PETS (11.4 GHz, test at SLAC)High-power dry load Hybrid
Variable high power splitter
4
Fabrication of accelerating structures
G. Riddone, 5th CLIC-ACE, 02/02/2010
T18 structures tested at SLAC/KEK showed excellent test results
consequent validation of design, machining and assembly procedure
NLC/JLC fabrication technology: validated to 100 MV/m (baseline for future CERN X-band
accelerating structures)
Baseline procedure
G. Riddone, 5th CLIC-ACE, 02/02/2010 5
Diamond machining (sealed
structures)
H2 diffusion bonding/brazing at
~ 1000 ˚C
Cleaning with light etch
Vacuum baking650 ˚C > 10 days
J. Wuang
J. Wuang
Application to CERN accelerating structures
• CERN previous assembly procedure was based on vacuum brazing at 800 ˚C several changes were needed for implementing the baseline procedure
• Following the post-mortem analysis of the two CERN accelerating structures T18 and T24, contamination (C, Ca) resulted to be the main problem cleanliness had to be seriously improved
G. Riddone, 5th CLIC-ACE, 02/02/2010 6
7
Baseline manufacturing flow
High precision diamond machining
Cleaning (light etch)
Brazing of coupler bodies, cooling
circuits, tuning studs(AuCu, 1020 °C)
Packaging and shipping
Brazing of couplers (H2, 1045 °C, AuCu)
Machining of couplers
Diffusion bonding of disk stack
(H2, 1020 °C)RF check and tuning
Baking (vacuum,
650 °C, >10 d)
QC
G. Riddone, 5th CLIC-ACE, 02/02/2010
New for CERN
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Inspections
G. Riddone, 5th CLIC-ACE, 02/02/2010
Microscopic inspection of disks before and after cleaning (on witness pieces)
Video inspections, SEM and microscopic inspections
Microscopic inspections before and after each relevant fabrication step
T18 KEK/SLAC design
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Machining at VDL
All dim
ensional checks
are conform
Shape tolerance ±2.5
mmDamped disk at
12 GHz
G. Riddone, 5th CLIC-ACE, 02/02/2010
New CMM (Coordinate Measuring Machine) under procurement at CERN
10
Cleaning
G. Riddone, 5th CLIC-ACE, 02/02/2010
SLAC cleaning procedure as a baseline
For degreasing Trichloroethane at SLAC replaced by Perchloroethylene
CERN procedure:(Firm AVANTEC Performance Chemicals):- TOPKLEAN MC 20A- PROMOSOLV 71IPA
Tool for holding the disks
Etching
J. Wuang
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Diffusion bonding
G. Riddone, 5th CLIC-ACE, 02/02/2010
1045 °C, 2 hcouplers
Couplers + disks
1020 °C, 1.5 h
TD24
TD24
T18KS
Disks
Bonding at CERN: few mbar H2 partial pressure (difference with SLAC): we are actively looking for a furnace at 1 bar H2 in Europe.
12
Accelerating structure TD24 after diffusion bonding under H2
Large grain size!
G. Riddone, 5th CLIC-ACE, 02/02/2010
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Assembly
G. Riddone, 5th CLIC-ACE, 02/02/2010
Assembly made on V-blocksVerification of the assembly (before and after bonding) with a new measurement column: straightness and tilt
Straightness
measurement ±2 mm
At SLAC
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RF check and tuning
G. Riddone, 5th CLIC-ACE, 02/02/2010
Bead pulling at 11.421GHz (old test-set-up)
Before shipping RF check and tuning were done and results were good
T24#1
New test set-up is under procurement for RF measurements
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Vacuum baking
G. Riddone, 5th CLIC-ACE, 02/02/2010
acel Serial vb732 on Station 4 on 10-JUN-08
1.00E-10
1.00E-09
1.00E-08
1.00E-07
1.00E-06
1.00E-05
1.00E-04
0.75 1.75 2.80 3.73 4.76 5.81 6.85 7.89 8.93 9.97 11.01 12.06 13.10 14.14 15.18 16.22 17.26 18.23 19.27
Days on Station
To
rr
tubePres
acel Serial vb732 on Station 4 on 10-JUN-08
0
100
200
300
400
500
600
700
0.75 1.75 2.80 3.73 4.76 5.81 6.85 7.89 8.93 9.97 11.01 12.06 13.10 14.14 15.18 16.22 17.26 18.23 19.27
Days on Station
De
gre
es
C
Avg.Temp
J. Wuang
1st baking: TD24 for CLEX,two-beam test stand
CERN furnace several mechanical adaptations were needed
10-9 mbar
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VESTIBULE CLEAN ROOM with AIR CONDITIONING
Clean room
G. Riddone, 5th CLIC-ACE, 02/02/2010
Clean room layout
Boxes under N2
Clean pieces
- After the failure of CERN ac. structures, it became clear that a clean room was indispensable
- Audits for relevant steps organized
Sealed bag under N2
RF measurement
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Fabrication of PETS at 11.4 GHz with damping material
G. Riddone, 5th CLIC-ACE, 02/02/2010
Bar length ~ 300 mmShape tolerance within specification: ± 7.5 mm
PETS for feasibility demonstration- under assembly - to be tested at SLAC
Damping material
Coupler
Minitank with bars inside
Fabrication flow for PETS (11,4 GHz)
G. Riddone, 5th CLIC-ACE, 02/02/2010 18
Procedure as close as possible to the baseline, but some difference due to design and infrastructures
Cleaning (NGL+solvent)
EB welding of the bars
QC
PETS
bar
s
Baking (vacuum, 200 C, 2 h)
Assembly of the 8 bars
Vacuum testEB welding of the bars
Packaging (N2)
RF check
Shipping to SLAC
Assembly of couplers-bars and
mini-tank
EB welding of tank
Final bake-out (150 C, 2h)RF check
FIN
AL A
SSEM
BLY
Fabrication of TBL PETS
G. Riddone, 5th CLIC-ACE, 02/02/2010 19
Prototype made by CIEMAT using conventional UHV best practice for cleaning and handlingCoupler is brazed, no heat treatment for PETS itself
The CERN production will be assembled in a clean room,The coupler will be vacuum brazed at CERN
Status: parts fabrication, assembly should start in April
S. Doebert
Production capability
G. Riddone, 5th CLIC-ACE, 02/02/2010 20
3 laboratories: - ac. structures SLAC/KEK and CERN- PETS CERN
5 qualified vendors for ac. structures: 2 (CERN), 2 (KEK), 1 (SLAC) 3 qualified vendors for PETSFor each structure, at least two units per lab. are manufactured (almost in parallel)For KEK/SLAC made structure, the assembly/baking is made at SLAC
- e.g. baking of two structures in parallelAt present, potential capability up to 20. structures per year
RF m
eas.
Baki
ng
1 wk1 wk
Total: 19 wks (about 5 months) Total: 18 wks (about 4.5 months)
10 wks
Assembly (EB welding )
6 wks
PRODUCTION CYCLE (ac. structures) PRODUCTION CYCLE (PETS @ 11.4 GHz)
ManufacturingManufacturing Baking
Tuni
ngAssembly (bonding)
4 wks 2 wks 3 wks10 wks
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Present structures: CERN, KEK, SLAC (base and fundamental program)
G. Riddone, 5th CLIC-ACE, 02/02/2010
CD10
TD24
under eng. designunder fabricationunder assemblyready for assemblyready for testing
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Present structures: CERN(base program)
G. Riddone, 5th CLIC-ACE, 02/02/2010
under eng. design
under fabrication
under assembly
ready for assembly
1 ac. structure (CLEX, TBTS)
2 ac. structures with wakefield monitors (CLEX, TBTS)
TBTS: two beam test standSATS: stand-alone test stand
Master schedule
G. Riddone, 5th CLIC-ACE, 02/02/2010 23Monthly revised during the KEK-SLAC-CERN collaboration WebEX meetingsLast revision:” 28.01.2010
Comparison to Jan 2009 schedule
• For production overall delay of about 4 months, although not on critical path• Priorities change as a function of test results• CERN structures: break of few weeks before decision to
adopt baseline procedure• Several steps of baseline procedure were new for CERN:
process qualification needed before application to a real structure
• Baseline procedure takes longer than the previous based on vacuum brazing at 800 °C
• Qualification of new vendors: several trials before achieving disks within specification
G. Riddone, 5th CLIC-ACE, 02/02/2010 24
Other structures
G. Riddone, 5th CLIC-ACE, 02/02/2010 25
Important involvement of other laboratories to exchange experience and to increase the market 900-mm long structures for PSI (X-FEL) and Elettra (Sincrotone
Trieste) with wakefield monitors 72 cells
Wakefield monitor design
Structure assembly
Towards CLIC structures • CDR
• Accelerating structure with all features: damping material, wakefield monitor and technical systems; under eng. design (first structure at the end of 2010). Assembly test with a prototype structure are scheduled in the coming weeks.
• PETS with on-off system: under design. On-off system to be tested in Q3, 2010
• Cost estimate in needed by 2010: launched dedicated studies with three companies/institutes
G. Riddone, 5th CLIC-ACE, 02/02/2010 26
Wakefield monitor
Damping material
Coupler
On-off system
AS
PETS
T4
T1
T0
Towards CLIC structures • From CDR to TDR
• Main linac prototype modules (3 by end of 2012) will be built to validate the technical systems in an integrated approach.
G. Riddone, 5th CLIC-ACE, 02/02/2010 27
• These modules will contain accelerating structures and PETS with all required features
• Industrialization and mass production development in collaboration with companies
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Conclusions
G. Riddone, 5th CLIC-ACE, 02/02/2010
• NLC/JLC fabrication technology validated for CLIC accelerating structures to 100 MV/m
• CERN is implementing NLC/JLC procedures (still in learning process)• Cleaning (etching)• Diffusion bonding at ~1040 °C (H2)• Vacuum baking
• Production capability up to 20 structures per year higher than available testing slots
• Involvement of other laboratories to exchange experience and expertise • CLIC structures with all features under design: first unit ready by end of this
year• Main linac prototype modules for CLEX will include CLIC several structures• Industrialization, mass production and cost study launched for few structure
configurations
SPARE
G. Riddone, 5th CLIC-ACE, 02/02/2010 29
30G. Riddone, 5th CLIC-ACE, 02/02/2010
Assembly of accelerating structures
T24T18 and before
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Comparison SLAC/CERN
G. Riddone, 5th CLIC-ACE, 02/02/2010
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Summary of comparison
G. Riddone, 5th CLIC-ACE, 02/02/2010
SLAC/KEK Fermilab CERN oldCERN new
(SLAC/KEK based)
Diamond machining √ √ √ √
Etch √ √ √ √
1000 ˚C pre-fire √ (Ar)
~ 1000 ˚C diffusion bonding
√ √
~ 1000 ˚C brazing √
~ 800 ˚C brazing √ (Ar, Au/Cu) √ (Vacuum, Ag/Cu) √Vacuum baking √ √ √Tank/sealed SEALED SEALED SEALED TANK/SEALED
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QUADRANTS - HDS thick qualification part according to CLIAAS300062 - KERN
(DE)
Achieved shape accuracy ± 2.1 µmRoughness Ra = 86 nm – 30 nm according to ISO 97
Achieved shape accuracy ± 1.3 µm
S. Atieh
G. Riddone, 5th CLIC-ACE, 02/02/2010
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Origins translation: X 16 µm and Z -8 µmShape accuracy is respected ± 2.5 µm
QUADRANTS - HDS thick qualification part according to CLIAAS300062 – DMP
(SP)
G. Riddone, 5th CLIC-ACE, 02/02/2010
S. Atieh
3535
T18 CERN - Inspection on iris 12
0 2 4 6 8 10Energy (keV)
0
10
20
30
cps
C
CuCu
Cu Cu
0 2 4 6 8 10Energy (keV)
0
5
10
15
20
25
cps
C
Ca
O
CuCu
Ca
Ca
Cu Cu
0 2 4 6 8 10Energy (keV)
0
10
20
30
cps
C
Cu
CuCu
Cu
0 2 4 6 8 10Energy (keV)
0
10
20
30
cps
Cu
Cu
Cu
Cu
Contamination between brazing and testing
35GR, BE/RF, 19.06.2009
C
C
Ca
T24#1 – CERN
G. Riddone, 5th CLIC-ACE, 02/02/2010 36