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Mikko Karppinen. Nb3Sn Coil Production for 11 T Dipole Model Magnets. Outline. 11 T Project Introduction Some Nb 3 Sn features Cable insulation Coil Fabrication Winding Curing Reaction Splicing Impregnation Instrumentation Handling Quality control

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Mikko karppinen

Mikko Karppinen

Nb3Sn Coil Production for 11 TDipole Model Magnets


Outline

Outline

  • 11 T Project Introduction

  • Some Nb3Sn features

  • Cableinsulation

  • Coil Fabrication

    • Winding

    • Curing

    • Reaction

    • Splicing

    • Impregnation

    • Instrumentation

    • Handling

  • Qualitycontrol

  • Long toolingprocurement plan


11 t dipole project

11 T Dipole Project

  • Create space for additional (cryo) collimators by replacing 8.33 T MB with 11 T Nb3Sn dipoles compatible with LHC lattice and main systems.

  • 119 Tm @ 11.85 kA

  • Phase 1: IR-1,5, and 2

    • 3 x 4 MB => 24 x 5.5 m CM + spares

  • Phase 2: Point-3,7

    • 2 x 4 MB => 16 x 5.5 m CM + spares

  • Joint development program between CERN and FNAL underway since Oct-2010.

MB.B8R/L

MB.B11R/L

15,66 m (IC to IC plane)

11 T Nb3Sn

3 m Collim

5.5 m Nb3Sn

5.5 m Nb3Sn

5.5 m Nb3Sn

3 m Collim.

5.5 m Nb3Sn


11 t dipole model program

11 T Dipole Model Program


11 t dipole magnetic design

11 T Dipole Magnetic Design

  • 60 mm bore and straight cold mass

  • Systematic field errors below the 10-4 level and conductor positioning at 50..100 µm level

  • 6-block design, 56 turns (IL 22, OL 34)

  • 14.85-mm-wide 40-strand Rutherford cable, no internal splice

  • Coil ends optimized for low field harmonics and minimum strain in the cable

B0(11.85 kA) = 11.25 T (20 % margin on the load-line @1.9K)


Nb 3 sn superconductor

Nb3Sn Superconductor

  • Nb3Sn critical parameters (Jc, Bc2 and Tc) very attractive for accelerator magnets

  • Requires (long) heat treatment @ 650..680 °C

    => Only inorganic insulation materials

  • Brittle, strain sensitive after reaction

  • Requires vacuum impregnation with resin

    => less efficient heat extraction by He

  • Magneto-thermal instabilities

    => small filaments, small strands, high RRR

  • Filaments ~50 µm (NbTi 6 µm)

    • Persistent current effects

  • Sensitive cabling compaction to avoid Jc degradation (cable stability)

  • “Wind and react”-process most commonly used for accelerator magnets

  • Cost ~5 x NbTi


Cable insulation

Cable Insulation

E-glass wrapping

Mica tape

S-2 Glass sleeving


Coil components

Coil Components

  • 316L End spacers (Selective Laser Sintering)

  • ODS (Oxide Dispersion Strengthened) Cu-alloy wedges


Winding

Winding

  • Relativelylowwinding tension of 15..30 kg (cablestability)

  • End regionsrequiregreat care to avoidinsulationdefects

  • Outer layer wound on curedinner layer and pre-formed inter-layer insulation


Ceramic binder

Ceramic Binder

  • Afterwinding of eachlayerceramicbinder CTD-1202 isapplied on the cableinsulation

  • Coils are curedatat80°C for 1 h and 150°C for 2h in a closedcavitymold.

  • Azimuthalcoil pressure isapprox. 20 MPa


Reaction

Reaction

  • Coilsize preciselydefined by closedcavitymold

  • Tooling design allowsfor coil expansion of 3%/1% in azimuthal/radial direction

  • Reactionwith positive argon pressure in the tooling

  • Modulartooling for easyscale-up


Reaction1

Reaction..

~10 days


Splicing

Splicing

  • Afterreaction the Nb3Sn leads are carefullycleanedavoidinganymechanicalstrain to the brittlecables

  • The splicesbetween Nb-Ti and Nb3Sn cables are solderedwithin the reactiontooling.


Impregnation

Impregnation

  • Reactedcoilistransferredfromreactiontoolinto the impregationmold

  • All voids are filledwithglassfiber and/or ceramicputty, and possible insulationdefects are repaired

  • 0.2 mm S2-cloth isapplied on the outer surface

  • ImpregnationwithCTD101K in the avacuum ovenat 30-50 mm Hg withepoxytemperature of 60° C

  • Curingat125° C for 21 h


Impregnation1

Impregnation..


Instrumentation

Instrumentation


Handling

Handling


Qc dimensional control cmm

QC: Dimensional Control (CMM)

Required accuracy < 20 µm


Qc photogrammetry

QC: Photogrammetry


Some cost indications

SomeCost Indications

220 m of insulated 40-strand Nb3Sn cable:

40 kCHF

A set of 23 end spacers:

10 (SLS) .. 20 kCHF (CNC)

Impreg. Tool (2.5 m):

50 kCHF

Impreg. System (2.5 m):

200 kCHF

Reaction furnace (2.5 m): 250 kCHF

Reaction tool (2.5 m):

50 kCHF


Scaling up

Large Magnet Facility in B180

Scaling-up..

Curing press – 15 m

Winding machine – 10 m


Long t ooling procurement plan

Long ToolingProcurement Plan

  • Winding machine available

    • Needs to beadapted: length, windingmandrel, integration of the additional spool, process control system upgrade

    • Design work to start in earlyDecember

    • First winding trials (withdummycable) scheduled as from mid-2013

  • Curingpressavailable

    • Curingmoulds to bedeveloped, design work to start in mid-2013

  • Reactionfurnace (6.5 m)

    • Market Survey completed

    • Invitation to tender, IT-3861/TE, completed

    • Contractsignature expected in January 2013

    • Delivery to CERN expected in the end of 2013

  • Impregnationchamber

    • Market Survey, MS-3898/TE, completed

    • IT to belaunched in January 2013

    • Contract signature expected in late April 2013

    • Delivery to CERN expected in first quarter of 2014


Acknowledgements

Acknowledgements

FNAL:

N. Andreev, G. Apollinari, E. Bartzi, R. Bossert, G. Chlachidze, F. Nobrega, I. Novitski, G. Wilson, A. Zlobin,...

CERN:

B. Auchmann, A. Ballarino, A. Bonasia, N. Bourcey, A. Cherif, S. Clement, L. Bottura, C. Kokkinos, B. Favrat, L. Favre, C. Fernandes, P. Fessia, R. Gauthier, G. Kirby, F. Lackner, G. Maury, J. Mazet, R. Moron-Ballester,

J-M. Mucher, L. Oberli, J-C. Perez, L. Rossi, T. Sahner, F. Savary, S. Sgobba, D. Smekens...


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