larp magnets fnal contribution to larp (lhc accelerator research program) fnal core-program support...

LARP Magnets

• FNAL contribution to LARP (LHC Accelerator Research Program)

• FNAL core-program support to LARP

DOE Annual Program Review - May 16-18, 2006

Giorgio Ambrosiofor the High Field Magnet group

LARP Magnets - G. Ambrosio 2DOE Annual Program Review, May 16-18, 2006

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 2009 Milestone

The LHC Accelerator Research Program (LARP) has a very challenging milestone at the end of 2009

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

1.

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


Milestone set in agreement with CERN


LARP 2009 Milestone

The LHC Accelerator Research Program (LARP) has a very challenging milestone at the end of 2009

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

1.

Technological Quadrupoles (TQ) for performance reproducibility


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


Milestone set in agreement with CERN

FNAL: Host lab for TQCs

FNAL: TQS coil winding & curing

FNAL: L2 coordination

FNAL: Design Study L2 coordination

FNAL: Host lab for LQsFNAL: Design

Study task leader

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


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

YokeGap

PreloadShim

ControlSpacer

Skin

Collar

YokeCollaringKey

Stress Relief Slotin inner pole

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


TQ Coil Fabrication

• TQ coil fabrication technology is based on FNAL techn.

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 for the 1st magnet series have been wound and cured at FNAL, reacted and impregnated at LBNL


TQC Design and Analysis

• FNAL has developed TQC design, and performed 2D and 3D magnetic and mechanical analysis

Coil stress < 150 MPa at all stages

3D magnetic analysis for ends and yoke optimization

3D mechanical analysis for end pre-load optimization:

1st time use of ANSYS birth-and-death capabilities to track epoxy crack propagation


TQC Mechanical Models

• Four mechanical models have been assembled and tested at FNAL in order to develop collaring procedure for Nb3Sn coils and check all fabrication steps

Stress in different longitudinal sections of the model during keys insertion:

Stresses are uniform within +/- 5 MPa during all process

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TQs Status and Plans

1st TQC “with collars”:– Coils are ready

– Assembly planned to start in mid of May

– Test planned in July

1st TQS “with Al-shell”:– Tested at LBNL in April

– Training started at 80% ssl

– Reached G = 190 T/m

– ~87% ssl or even more, analysis is in progress

TQS01 training history

Numbers on top show coil where quench started


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 Quadrupoles

FNAL, LBNL, BNL

LARP LQ Design Study

LARP Long RacetracksBNL, LBNL, FNAL 2006

2007

2008

2009


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 (preloaded using bladders and keys)

Developed at LBNLFNAL contributions:

L2 coordination of Supporting R&D (G. Ambrosio)FNAL scientists and engineers are part of LR working groupSub-task: technology transfer from the LR to the LQ involves FNAL engineers and technicians

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

From 0.3 m to 3.6 m


FNAL Long Mirror

• FNAL “Mirror magnet” is a cos-theta dipole where a coil is substituted by iron blocks

• Plan: 2m – 4m mirror magnets

Front view of mirror magnet

The plan is to base the scale-up on a well understood design and fabrication technology

FNAL successfully fabricated 3 dipoles and 1 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, …)


Other parts of SC magnet R&D

• FNAL has a major role in Design Studies: – LARP L2 coordinator (Zlobin) – LARP Long Quadrupole DS task leader (Ambrosio)– several scientists involved in different designs (inside and outside LARP)

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

materials, in different conditions (pressure, field, temperatures)

• … also in Magnet testing:– LARP magnet integration coordinator

(Feher)– 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


0

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1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

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Not including G&A

LHC Project R&D LARP Magnet R&D

High Field Magnets

TD Magnet R&D

Budget and Resources

Actual or budgeted Projected Present resources: 5 physicists 8 engineers 2 designers 9 technicians (~22 FTEs) + support. staff

(~27 FTEs)

• Present Core Program budget ~$2.5-3M/year and present LARP Magnet R&D budget will allow reaching LARP goals and HFM long term goals

• 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


Conclusions

• The SC Magnet R&D program at FNAL is fully engaged in LARP goals and plan with a leading role in several major areas

• The core-program is supporting LARP offering risk mitigation and diversity

• The Long Quadrupoles (2009 deadline) and future prototypes to demonstrate the possibility of a high-luminosity LHC-IR upgrade will be built at Fermilab“We understand and feel our responsibility,

we are doing all possible efforts to accomplish this mission!”

larp magnets fnal contribution to larp (lhc accelerator research program) fnal core-program support...

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