HQ structures Working group

1. HQ structuresWorking group M. Anerella, D. Bocian, S. Caspi, J. Cozzolino, P. Ferracin, A. Milanese, S. Prestemon November 2, 2010

2. Outline Paolo Ferracin • Design features and FEA results comparison of the two structures • Possible synergies • Options/plans for testing two coils in the same structure (to check the performance using half-length coils) • Options/plans for a test that will incorporate a pressure vessel over the aluminum shell • Heat transfer calculations and design features for improved cooling

3. Outline Paolo Ferracin • Design features and FEA results comparison of the two structures • Possible synergies • Options/plans for testing two coils in the same structure (to check the performance using half-length coils) • Options/plans for a test that will incorporate a pressure vessel over the aluminum shell • Heat transfer calculations and design features for improved cooling

4. HQ structures • HQ LBNL • HQ BNL Paolo Ferracin

5. Coil-Collar alignment and collar • Aluminum bolted collars • Collars locked by bolts • Key locked from beginning of assembly • Little or no coil stress • No press required • Aluminum keyed collars • Two tapered keys per quadrant • Collar mid-plane closes after keying • Little or no coil stress • Bladders system as “collaring press” Paolo Ferracin

6. HQ BNLCollaring fixture with new bladders Paolo Ferracin

7. From collar to shell • Pads – bladders – yoke • Collar-pad alignment: collars nested into pads • Masters and keys to align pad and yoke • Pad and yoke 45° gap always open • Alignment transferred from 45° to mid-plane • Full contact collar-pad • Inner yoke – bladders – outer yoke • Collars - Inner yoke alignment: key - slot • 45° key to align inner yoke to fiducials • Inner and outer yoke mid-plane always open • Alignment always along the 45° axis • Contact collar- inner yoke in the mid-plane Paolo Ferracin

8. Shell-bladders and room temperature pre-load • One 50 mm bladder per octant • 25 mm thick shell • 45 MPa in bladders to open 0.6 mm • 100 MPa shell tension • 39% of the total force (coming from the shell) intercepted by the collar-key • Two 40 mm wide bladders per octant • 25 mm thick shell • 30 MPa in bladders to open 0.3-0.6-0.8 mm • 125 MPa shell tension Paolo Ferracin

9. Shell-bladders and room temperature pre-load Pole shim: .79mm Middle shim: .62mm Mid-plane shim: .25 mm Paolo Ferracin HQ BNL

10. Shell-bladders and room temperature pre-load • Coil peak stress: -93 MPa • Coil peak stress: -120 MPa Paolo Ferracin

11. Cool-down • Shell stress: 210 MPa • 20% of the total force (coming from the shell) intercepted by the collar-key • Shell stress: +220 MPa Paolo Ferracin

12. Cool-down • Coil peak stress: -195 MPa • Coil peak stress: -188 MPa Paolo Ferracin

13. Excitation • Coil horizontal displacement on the mid-plane during excitation • Displacement in the outer radius • From –0.419 mm to -0.372 mm • Delta: +47 micron • Coil horizontal displacement on the mid-plane during excitation • Displacement in the outer radius • From –0.434 mm to -0.330 mm • Delta: +104 micron Paolo Ferracin

14. Excitation • Coil peak stress: -185 MPa • Coil peak stress: -135 MPa Paolo Ferracin

15. End support • Stainless steel (Nitronic 40) end plate • 50 mm thick • Aluminum axial rods • 34 mm diameter • Stainless steel end plate 127 mm thick with 12.7 mm ss shell and bullets Paolo Ferracin

16. Outline Paolo Ferracin • Design features and FEA results comparison of for the two structures • Possible synergies • Options/plans for testing two coils in the same structure (to check the performance using half-length coils) • Options/plans for a test that will incorporate a pressure vessel over the aluminum shell • Heat transfer calculations and design features for improved cooling

17. Possible synergies Paolo Ferracin • FEM • Same bladders (old or new) • Same collars • shape and dimension • Aluminum segmented shell • LHe vessel • Fiducials • End pre-load

18. Bladder Development 1 1st bladder design – testing complete, unsuccessful Test Setup (left): Die springs (not shown) resist initial load After 6mm extension, fixture built to withstand 10kpsi Design As-Built Problem: Friction on sides prevented full extension & transmission of pressure Angled relief in fixture cavity for test #2 did not help Alternate Structure Work – CM15 11/2/10

19. Outline Paolo Ferracin • Design features and FEA results comparison of for the two structures • Possible synergies • Options/plans for testing two coils in the same structure (to check the performance using half-length coils) • Options/plans for a test that will incorporate a pressure vessel over the aluminum shell • Heat transfer calculations and design features for improved cooling

20. Two coils on the same structure Paolo Ferracin Field, end forces, required pre-load on RE to be modeled and analyzed Some practical issues with instrumentation wires No show stoppers

21. Outline Paolo Ferracin • Design features and FEA results comparison of for the two structures • Possible synergies • Options/plans for testing two coils in the same structure (to check the performance using half-length coils) • Options/plans for a test that will incorporate a pressure vessel over the aluminum shell • Heat transfer calculations and design features for improved cooling

22. Pressure vessel Paolo Ferracin Detailed design in progress No particular issue forseen

23. Outline Paolo Ferracin • Design features and FEA results comparison of for the two structures • Possible synergies • Options/plans for testing two coils in the same structure (to check the performance using half-length coils) • Options/plans for a test that will incorporate a pressure vessel over the aluminum shell • Heat transfer calculations and design features for improved cooling

24. NbTi “Phase I” upgrade quadrupole Paolo Ferracin • Heat-load of about 500 W • Heat exchangers with minimum inner diameters of 65 mm

25. Heat transfer and cooling • Slots between pads • 80 mm holes Paolo Ferracin

26. load from cable Paolo Ferracin

27. Conclusions Paolo Ferracin • Design features and FEA results comparison • Both structure claimed to provide load and alignment • Different emphasis on loading or alignment • Comparable coil stresses (some issue at full field) • Possible synergies • Everything but iron parts • Options/plans for testing two coils in the same structure • Analysis to check forces and pre-load but no show stoppers • Options/plans for a test that will incorporate a pressure vessel over the aluminum shell • Design underway, no plans to test it, but it can be done • Heat transfer calculations and features for improved cooling • Holes to be implemented in HQ LBNL • Heat to be removed from the coil through pole pieces

28. HQ structures • HQ LBNL • HQ BNL Paolo Ferracin