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SRF Development at daresbury laboratory A. Wheelhouse ASTeC, STFC Daresbury Laboratory. 2 nd PASI Workshop, RAL 3 rd – 5 th April 2013. Outline. Mini PIPSS / IPS Programme Aims & Objectives Progress & Results SRF Cryomodule Development Aims & Objectives Progress Summary.

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srf development at daresbury laboratory a wheelhouse astec stfc daresbury laboratory

SRF Development at daresbury laboratoryA. WheelhouseASTeC, STFC Daresbury Laboratory

2nd PASI Workshop, RAL 3rd – 5th April 2013

outline
Outline
  • Mini PIPSS / IPS Programme
    • Aims & Objectives
    • Progress & Results
  • SRF Cryomodule Development
    • Aims & Objectives
    • Progress
  • Summary

4th April 2013

PASI Workshop A Wheelhouse

mini pipss ips programme
Mini PIPSS & IPS Programme

PASI Workshop A Wheelhouse

slide4
Aims
  • The fundamental remit of the Mini PIPSS & IPS, Industry Partnership Schemes is to develop the capability of UK industry in the manufacturing of superconducting RF cavities
  • Mini PIPSS
    • Fabrication of a single cell niobium cavity (1-year)
  • IPS
    • Fabrication of a bulk niobium 9-cell accelerating structure (3-year)
      • Cell to cell alignment
      • Tuning robustness and uniformity
      • Tolerance management
      • Cleaning/processing compliance
      • RF surface integrity management
  • Technology directly applicable to future large scale accelerator facilities.
  • Opportunity for Daresbury Laboratory and Shakespeare Engineering Ltd to develop unique capabilities in the UK
  • Enable Shakespeare Engineering Ltd to exploit the large SRF commercial opportunity

PASI Workshop A Wheelhouse

objectives
Objectives
  • Mini PIPSS
    • Fabrication of a single cell TESLA SRF cavity
    • Acceleration gradient > 15 MV/m at a Qo better than 1 x 1010
  • IPS
    • Fabrication of a 9-cell TESLA SRF cavity which will be qualified in 2 ways:-
    • Accelerating gradient > 20 MV/m at a Qo better than 1 x 1010after conventional Buffer Chemical Polishing (BCP) is performed
    • Accelerating gradient > 30 MV/m at a Qo better than 1 x 1010 when Electro-Polishing (EP) chemical processing is performed
  • Aim to provide a clear indication of Shakespeare’s capability and assist in qualifying them as a potential supplier

PASI Workshop A Wheelhouse

cell and beampipe forming
Cell and Beampipe Forming
  • Cavity half cells and beampipes fabricated by Shakespeare Engineering
  • Half cells pressed on a 60 t hydraulic press
    • Pressing performed in 3 operations
  • Beampipes were spun using a CNC spinning machine
    • Eliminates additional welded seam joint
    • Spinning of cones performed with intermediate heat-treatments
    • Beam tube finally formed on a mandrel
  • 3 single cell cavities welded at JLab

4th April 2013

PASI Workshop A Wheelhouse

pipss 01 jlab
PIPSS #01 (JLab)

Multipactor

  • Achieved 15.7 MV/m with a Q0 of 1.15 x 1010

Target

  • CW and pulsed conditioning
  • Gradient - 17.6 MV/m with a Q0 of 2.17 x 109

4th April 2013

PASI Workshop A Wheelhouse

pipss 01 jlab1
PIPSS #01 (JLab)
  • Additional BCP etch
      • Approximately 41µm removed

4th April 2013

PASI Workshop A Wheelhouse

pipss 01 jlab2
PIPSS #01 (JLab)
  • Vac furnace run at 600ºC for 10 hours
  • Plus an additional BCP etch
      • Approximately 28µm removed
      • Further high pressure rinses

4th April 2013

PASI Workshop A Wheelhouse

pipss 01 jlab3
PIPSS #01 (JLab)
  • Further high pressure rinses

4th April 2013

PASI Workshop A Wheelhouse

pipss 02 daresbury
PIPSS #02 (Daresbury)
  • Acid fume cupboard used to perform the BCP etch
  • Thickness removed measured on a sample piece which doubled as a stirrer
  • Acid temperature monitored
  • 85µm removed in 2 etch runs
    • Cavity turned up the other way for the 2nd run
  • HPR performed for 1 hour
  • Cavity sealed in a ISO4 class cleanroom

PASI Workshop A Wheelhouse

pipss 02 evaluation
PIPSS #02 Evaluation
  • VTF manually filled from a 1000lt dewar
  • Reduced performance achieved on second cavity processed at DL
  • Ineffectivetemperature control on the BCP etch
  • Improvements to BCP processing is underway
    • Further testing to be performed

PASI Workshop A Wheelhouse

pipss 03 fnal
PIPSS #03 (FNAL)

EB weld inspection

FERMI Lab Standard Preparation

  • EB weld good
    • Some inclusions

Electro-polishing monitoring

4th April 2013

PASI Workshop A Wheelhouse

pipss 03 tests
PIPSS #03 Tests

FermiLab Tests

  • Cavity tested at 2K
  • Maximum accelerating gradient 25 MV/m with Q0=1.5x1010
  • Gradient limited by a quench
    • First quench at 18 MV/m
    • Quenched twice at 21 MV/m
    • Finally quenched at 25 MV/m
    • Limited by repetitive quenches at 25 MV/m which showed no sign of conditioning after 20 mins
  • No field emission above background was observed
  • Some multipacting was noted at around 18 MV/m
    • Instabilities in Ptransmitted signal were observed
    • Common ILC-shape multipacting range
    • Multipacting processed
  • Successfully met target

4th April 2013

PASI Workshop A Wheelhouse

pipss 03 tests1
PIPSS #03 Tests

Target

4th April 2013

PASI Workshop A Wheelhouse

pipss 03 further qualification
PIPSS #03 - Further Qualification
  • Further processing performed
  • Cavity has been CBP
    • Removing ~180µm
  • Light 30µm electro-polish to remove a weld inclusion
  • Vacuum bake at 800ºC
  • Cavity to be tested 5/4/13

CBP

Typical before and after CBP

4th April 2013

PASI Workshop A Wheelhouse

ips programme
IPS Programme
  • 3-year programme on-going
  • Cavity drawings complete
  • Tooling has been manufactured
  • Pressing trials being completed with Copper
    • Assessing repeatability and reproducibility
  • Niobium half cells to be pressed soon
  • Further beampipe spinning trials
    • Thicker sheets
  • SRF infrastructure development
    • Automated BCP process
    • Automated HPR
  • It is hoped that FNAL can continue to assist in qualifying Shakespeare with this structure.

9-cell cavity drawings

BCP facility

HPR stand

4th April 2013

PASI Workshop A Wheelhouse

srf cryomodule development
SRF Cryomodule Development

ALICE

4th April 2013

PASI Workshop A Wheelhouse

aims objectives
Aims & Objectives
  • To lead the design of a new, high current and world leading cryomodule.
  • To educate and demonstrate effective:
    • Processing,
    • Handling,
    • Assembly,
    • Testing,
    • QA processes.
  • To integrate the new cryomodule onto ALICE
  • Commission cryomodule + cryogenics systems
  • To validate cryomodule performance with beam

4th April 2013

PASI Workshop A Wheelhouse

srf cryomodule
SRF Cryomodule
  • International collaboration initiated in early 2006:
    • ASTeC (STFC)
    • Cornell University
    • DESY
    • FZD-Rossendorf
    • LBNL
    • Stanford University
    • TRIUMF (2009)
  • Fabricate new cryomodule and validate with beam.
  • Dimensioned to fit on ALICE:
    • Same CM footprint
    • Same cryo/RF interconnects
    • ‘Plug Compatible’

Existing Cryomodule on ALICE

ERL (New) Cryomodule

4th April 2013

PASI Workshop A Wheelhouse

srf cryomodule1
SRF Cryomodule

Existing Cryomodule on ALICE

ERL (New) Cryomodule

4th April 2013

PASI Workshop A Wheelhouse

coupler conditioning
Coupler Conditioning
  • High power conditioning of the CPI input couplers:
    • Up to 30 kW (pulsed)
    • Up to 10 kW (CW)
  • For these tests, couplers water/air cooled only
  • No vacuum activity seen

Pulsed Conditioning

4th April 2013

PASI Workshop A Wheelhouse

coupler conditioning1
Coupler Conditioning
  • High power conditioning of the CPI input couplers:
    • Up to 30 kW (pulsed)
    • Up to 10 kW (CW)
  • For these tests, couplers water/air cooled only
  • No vacuum activity seen

CW Conditioning

4th April 2013

PASI Workshop A Wheelhouse

cryomodule assembly
Cryomodule Assembly

HOM assembly

µ metal installation

Cavity wiring

Cavity string

4th April 2013

PASI Workshop A Wheelhouse

cold tests off line
Cold Tests (Off-line)
  • Check the cryogenic performance
  • Understand the processes and establish commissioning and operating procedures
  • Validate instrumentation
  • Cavity frequency verification
    • Issue with tuner sticking had to be resolved
  • Identify and resolve any unknown issues
  • 80K tests successfully completed
  • Attempted to cool-down to 4K however:
    • Large temperature gradient between the two cavities
    • Helium reservoirs did not fill completely
  • Result of blockage between cavity bottom fill connection and excessive heat load at the input transfer line

4th April 2013

PASI Workshop A Wheelhouse

cryomodule evaluation
Cryomodule Evaluation
  • Cryomodule installed and cooled to 2K
  • Optimisation presently being performed on the cryogenic system

Evaluation Programme:-

  • Establish gradient and Q0
  • Measure Lorentz force detuning at high gradient
  • Performance measurements with piezo tuners
  • Determine DLLRF control limitations wrtQext
  • Evaluate the effect of beam loading with DLLRF, piezo control for various Qextlevels under pulsed and CW conditions
  • Characterise cavities in CW mode at high gradient:
    • Evaluate thermal transients across cavity string and 2-phase line
  • Synergies with PXIE operational requirements to be evaluated

Cryomodule installed on ALICE

4th April 2013

PASI Workshop A Wheelhouse

summary
Summary
  • Verified the fabrication of a single cell SRF cavity
  • 9-cell SRF cavity and infrastructure development progressing
  • UK SRF capability in a stronger position thanks to FNAL collaboration
  • Cavity string integrated into the cryomodule
  • Cryogenically commissioned cryomodule off-line
  • Cryomodule now installed in ALICE
  • Cryomodule characterisation about to commence

4th April 2013

PASI Workshop A Wheelhouse