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Results of short module and qualification strategy

Results of short module and qualification strategy. PIMS production meeting 26-27 February 2013 Rolf Wegner. Production qualification, April 2012. Status of machining qualification, 19.04.2012:. Review of steps towards qualification. Meeting at CERN in March 2012:

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Results of short module and qualification strategy

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  1. Results of short module and qualification strategy PIMS production meeting 26-27 February 2013 Rolf Wegner

  2. Production qualification, April 2012 Status of machining qualification, 19.04.2012: PIMS production meeting 26-27 February 2013 Rolf Wegner

  3. Review of steps towards qualification • Meeting at CERN in March 2012: • * machining procedures optimised (=> clamping) [parts seen 5 to 10 times out of tolerance] • * specifications very tight; small performance degradation <=> accepting certain deviations from specifications (EDMS 1209460) • * recommendation: final machining on a lathe • Meeting at NCBJ in April 2012: • * green light for rough machining of discs for series • * Quality Assurance Report form defined • Mai 2012: • * new weld qualification with cosmetic pass + repair of weld for ring G_13-14 • * preliminary metrology end disc M_1=> green light to finish end disc M_14 and disc M_6-7 • June 2012: • * brazing test finished PIMS production meeting 26-27 February 2013 Rolf Wegner

  4. Review of steps towards qualification • July 2012: • * QA report disc G_2-3 ok, end disc M_1 ok, shipment to CERN • * QA report disc M_6-7, re-machining of assembly ø524 requested • * QA report end disc M_14, agreed on adaptation of ring M_13-14 - side 14 for assembly ø524 • September 2012: • * welding of ring M_13-14 ok, defect on ring M_1-2 => sent for repair to Julich=> using ring G_13-14 as 2nd ring for short module • * brazing test evaluated at CERN (visual inspection, ultrasound & vacuum tests), very good result, => green light to produce waveguide ring cavity M • * disc G_2-3, end disc M_1 inspected at CERN => green light for finishing all discs cavity M • November 2012: • * QA report ring M_13-14 PIMS production meeting 26-27 February 2013 Rolf Wegner

  5. Review of steps towards qualification • December 2012: • * QA report re-machined ring G_13-14 => green light for finishing all rings cavity M • * end disc M_14, disc M_6-7, ring M_13-14 and ring G_13-14 arrived at CERN • January 2013: • * QA report discs M_2-3, M_12-13 • February 2013: • * QA report discs M_4-5, M_10-11 PIMS production meeting 26-27 February 2013 Rolf Wegner

  6. Quality Assurance Reports • => "Disc G_2-3 - Analysis & Comparison CERN.xlsx" • * report form from NCBJ exactly as desired • * analysis to specifications • * analysis to acceptable dimensions • * comparison to CERN measurements • metrology machine accuracy: ± 6 μm • => comparison precision: ± 12 μm • => specifications 500 mm ± 10 μm difficult to machine and difficult to measure !!! • results quite similar (a few small points to discuss tomorrow) PIMS production meeting 26-27 February 2013 Rolf Wegner

  7. Vacuum tests at CERN end discs M_1, M_14; disc G_2-3; ring M_13-14 all leak rate < 2*10-11mbar*l/s PIMS production meeting 26-27 February 2013 Rolf Wegner

  8. Brazing test at NCBJ • good visual impression • vacuum tight (leak rate <1*10^-10 mbar l/sec) • good ultrasound analyse results • Agostino: ”It is hard to do itbetter” • => Green light for brazing of WG ring of 1st cavity (25.09.12) PIMS production meeting 26-27 February 2013 Rolf Wegner

  9. Machined parts, end discs M_1 and M_14 * to acceptable dimensions PIMS production meeting 26-27 February 2013 Rolf Wegner

  10. Machined parts, disc M_6-7 * to acceptable dimensions PIMS production meeting 26-27 February 2013 Rolf Wegner

  11. Machined parts, ring M_13-14 * to acceptable dimensions PIMS production meeting 26-27 February 2013 Rolf Wegner

  12. Machined parts, disc G_2-3 * to acceptable dimensions PIMS production meeting 26-27 February 2013 Rolf Wegner

  13. Machined parts, ring G_13-14 * to acceptable dimensions • Ring G_13-14 was intended for machining tests to validate milling technology (spare material of CERN prototype) • port welding defect, weld was repaired, further machining tests • port welding defect of ring M_1-2, ring G_13-14 is used for assembly check of short module PIMS production meeting 26-27 February 2013 Rolf Wegner

  14. Machined parts, summary • discs analysed are close to acceptable dimensions=> remarkable progress made since last year (improvement of factor 5 to 10 on most tolerances) assembly diameter 524.720-0.025+0 seem to be well under control (QA reports discs M_2-3, M_4-5, M_10-11, M_12-13)however, deviations on * coaxiality axis/524/538mm (=> inter-cavity alignment – aperture reduction)* perpendicularity axis/faces (=> inter-cavity alignment – aperture reduction)* cooling channel finishing • => we need to analyse remaining discs of cavity M at CERN for qualification • ring M_13-14 is close to acceptable dimensions=> remarkable progress made since last year (machining procedures were developed [weld deformation] and most acceptable tolerances reached) assembly diameter 524.720+0.050+0.075seem to be well under control (also ring G_13-14)however, deviations on * coaxiality538/524mm (=> inter-cavity alignment – aperture reduction)* perpendicularity axis/faces (=> inter-cavity alignment – aperture reduction)* only 1 ring as sample • => we need to analyse remaining rings of cavity M at CERN for qualification PIMS production meeting 26-27 February 2013 Rolf Wegner

  15. Short module: assembly test • assembly was very smooth • only end disc M_14 was slightly difficult to place correctly, small gap remains=> Thierry will use dense point weldings before final weld end disc M_14 ring M_13-14 disc G_2-3 ring G_13-14 end disc M_1 PIMS production meeting 26-27 February 2013 Rolf Wegner

  16. Short module: RF check, preliminary results z-axis: assembly order z=0 end disc M_1 - ring G_13-14 - disc G_2-3 - ring M_13-14 - end disc M_14 … to z=max PIMS production meeting 26-27 February 2013 Rolf Wegner

  17. Short module: RF check, preliminary results • assembly had to be clamped, otherwise Q ~ 1'000, f_mode_1 ~ 349.200 MHz • Q-values reasonable, will improve with welding (~ 10% seen for prototype) • field profiles look very similar, slight deviations for mode 2 • ~ 700 kHz frequency difference between measurement and simulations • simulation uncertainty ~± 500 kHz (mesh limit, 2 cells, different geometry) • tuning range (island + plunger) for mechanical tolerances + simulation uncertainties: ± 600 kHz • =>further analysis needed to understand difference in frequency simulations/measurement • =>simulationmodel needs to be checked carefully (systematic difference 700 kHz) PIMS production meeting 26-27 February 2013 Rolf Wegner

  18. Next steps • qualification of vacuum check • * visit of NCBJ experts to CERN, March 25-26th, tests of end disc, disc, ring • * shipment of equipment to NCBJ (~ 100 kg, ~ 200 pieces, ~ 25'000 CHF) • * visit to NCBJ with CERN experts, intended before April 19th (material !)tests of end disc, disc, ring • vacuum check of discs and rings cavity Mat NCBJ • production and checks of waveguide ring cavity Mat NCBJ • check of discs and rings cavity M at CERN => qualification for series production • check of waveguide ring cavity M at CERN => qualification for series production • in order to advance production, maybeintermediate green light for finishing cavity 2 PIMS production meeting 26-27 February 2013 Rolf Wegner

  19. Production qualification, February 2013 Status of qualifications, 25.02.2013: PIMS production meeting 26-27 February 2013 Rolf Wegner

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