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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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slide1

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 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
qc dimensional control cmm
QC: Dimensional Control (CMM)

Required accuracy < 20 µm

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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