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Transcript of ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE...
![Page 1: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/1.jpg)
ILCAmericas
Cavity and Cryomodule R&D
Shekhar MishraILC Program
Fermilab
Talk presented at DOE Annual Program Review
Breakout Sessions – Wednesday, May 17
![Page 2: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/2.jpg)
ILCAmericas ILC Cavity and Cryomodule R&D Goals
• ILC R&D at Fermilab is focused to address the high priority ILC design and technical issues as recommended by ILC-TRC and recently by ILC-GDE R&D Board.
• The main thrust of the ILC Cavity and Cryomodule R&D is to establish technical capabilities in the Superconducting Radio Frequency (SRF) Cavity and Cryomodule technology. The main goals are
– Cavity technology development in the US to routinely achieve > 35 MV/m and Q ~0.5-1e10,
– ILC Cryomodule design, fabrication (cost reduction)
– Fully tested basic building blocks of the Main Linac (Evaluate the integration, reliabilities issues and value engineering).
– LLRF, Instrumentation and Controls development for Main Linac
• Development of U.S. laboratories and industrial infrastructure for the fabrication, processing and testing of high performance SRF cavities, Coupler, Tuner, HOM and Cryomodule.
![Page 3: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/3.jpg)
ILCAmericas Plans for 35 MV/m• Cavity Fabrication, Preparation, Surface Processing, Clean Surface and Clean
environment is the key to achieving a high gradient in the ILC cavities.
• Fermilab is leading the US effort with collaborating laboratories.
– Niobium is being scanned at Fermilab. (Need larger inventory. There are variation from batch to batch, vendor to vendor etc.)
– Cavity is being fabricated at industry under the supervision of Fermilab and Cornell. Jlab will join this soon.
– Cavity is being processed (BCP and EP) and vertical tested at Cornell, Jlab and will be processed at ANL/FNAL
• The processing infrastructure needs more focused effort. Experiences from DESY and KEK suggest that we build this facility at where cavity is dressed, horizontally tested and put in a string.
• We are in process of having this facility at Fermilab by 07.
• Fermilab is fabricating 8 (FY05), 16(FY06), 24-36 (FY07) ILC cavities. More could be needed to
• These cavities will be systematically processed and testing. We would systematically collect data during the fabrication, processing and testing.
• These data would be analyzed for co-relations to understand the process.
![Page 4: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/4.jpg)
ILCAmericas ILC Cavity: R&D
• Material R&D: Fine, Large, Single Crystal
• Fabrication– A number of minor modifications and improvements could
be implemented without impact to the basic cavity design.
• Cavity Preparation
• Buffer Chemical Processing
• Cavity Processing R&D– Electro-polishing (EP) System– High Pressure Rinsing (HPR)– Clean Assembly Procedure
![Page 5: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/5.jpg)
ILCAmericas Cavity Fabrication
• Industrial production of the cavity by Fermilab (ACCEL, AES)
• 8 TESLA Design Cavities ordered• 10 ILC Baseline Design Cavities in FY06
• Cavity fabrication at Jlab• 2 ILC Baseline design and Type-IV• 2 Low Loss Cavity• Several single cell for Process and Material R&D • Material R&D (Fine Grain, Large Grain, Single Crystal)
• Cavity fabrication at Cornell• Re-Entrant Cavities (70 mm)• Re-Entrant Cavities (60 mm)• Several single cell for Process R&D
• Cavity fabrication at KEK (US-Japan)• Cavities of TESLA, Low Loss and ICHIRO design
![Page 6: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/6.jpg)
ILCAmericas
Cavity Fabrication, Processing and Testing Road Map
Cavity FabricationBy Industry
Cavity Dressing &Horizontal Testing
@ Fermilab
BCP and EPProcessing @ Cornell
BCP and EPProcessing
@ Jlab
BCP and EPProcessing @ ANL/FNAL
Vertical Testing @ Cornell
Vertical Testing @ Jlab
Vertical Testing @ FNAL
Exists
Developing
![Page 7: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/7.jpg)
ILCAmericas Cavity Measurements
• RF measurement of the ACCEL Cavities at Fermilab.
Accelerating field amplitude in cavity axes.
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
0 200 400 600 800 1000 1200Z, mm
Am
plit
ud
e
ACCEL6 ACCEL7 ACCEL9
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ILCAmericas ILC Cavity Material Grain size R&D at Jlab
• Study of Single Cell large grain niobium from CBMM, Heraeus and Ningxia
• 5 single cell cavities each from these vendors will be fabricated for statistics.
• Two 9-cell cavities are being fabricated for Fermilab using CBMM ingot.
Large Grain TESLA Cavity Shape SC, Chinese Nb
1.00E+09
1.00E+10
1.00E+11
0 5 10 15 20 25 30 35
Eacc [MV/m]
Q0
Test#1/2/3/4
Q - drop
Quench 29 MV/m
Quench @ 33.3 MV/m
Ningxia
Large Grain TESLA Cavity Shape SC, WC_Heraeus Nb
1.00E+09
1.00E+10
1.00E+11
0 5 10 15 20 25 30 35
Eacc [MV/m]
Q0
Test#2/4
Quench at 34.4 MV/m
HeraeusLarge Grain TESLA Cavity Shape SC#2, Ingot"D"
1.00E+09
1.00E+10
1.00E+11
0 5 10 15 20 25 30 35
Eacc [MV/m]
Q0
T=1.99K Series2
Test #1/2Test #1
Quench at 31.2 MV/m
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ILCAmericas
50 MV/m in Single Cells !Lower Surface Magnetic Field & Lower Losses
Re-entrant
CornellKEK
Low Loss
Jlab
KEK
Tesla Shape
Need Multi-cells Next
New Shapes Breakthrough
![Page 10: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/10.jpg)
ILCAmericas
Fabricated at Cornell
Proof of Principle Results: Eacc = 47 - 52 MV/m
/Ichiro
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ILCAmericas
60 mm aperture similar to LL shape -> 16% lower Hpk/Eacc
New Reentrant Cavity Shape
Work done in Collaboration with KEK
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ILCAmericas ILC Cavity Processing• We are using infrastructures at the collaborating laboratories to develop the
processing capabilities and parameters in USA to achieve 25 MV/m with BCP and 35 MV/m with EP.
• These facilities are also being used to train people.
• Cornell:– BCP and HPR – Vertical EP
• Jlab– EP
• Fermilab and ANL (New Facility)– BCP – EP
• We are also sending Fermilab staff to DESY for participation and training in surface processing, vertical and Horizontal testing.
![Page 13: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/13.jpg)
ILCAmericas Check Reproducibility of HPR
Cornell Re-entrant Cavity
3.9.9
3.9.10
Work done in Collaboration with KEK
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ILCAmericas
BCP Complete
First ACCEL ILC Cavity at Cornell
HPR Complete
3.9.3.1
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ILCAmericas Vertical Test of ACCEL Cavity
Fermilab is sending engineering staff and technician to participate in the BCP and vertical testing at Cornell.
ACCEL8_21apr06
1.000E+09
1.000E+10
1.000E+11
0 5 10 15 20
Eacc (MV/M)
Q
QuenchNo Radiation
60 um BCP (nominal) + 50 um at ACCEL
Low Field: Q >1010, Eacc = 17 MV/m, (Quench)
Q
Eacc (Mv/m)
![Page 16: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/16.jpg)
ILCAmericas Goals for EP Development at JlabEstablish EP processing for ILC 9-cell cavities at Jlab
• Commissioning EP cabinet with Spare DESY 9-cell cavity
• Perform HPR, assembly and testing with S35 cavity to analyze procedure effectiveness and reproducibility
• Investigate standard process procedures to gain a better understanding of current issues (Sulfur precipitation, HF loss during use)– Identify and develop relevant process metrics and QA steps
• Establish and document procedures– Aim is uniform reproducible etching with clean surfaces after rinsing
• Process, test, qualify and prep cavities for FNAL string assembly
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ILCAmericas
HPR and Assembly
Alignment Cage
Electropolish Development for ILC
Jlab EP Cabinet
3.9.3.2
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ILCAmericas
EP System Alignment Frame and Cathode with ILC Cavity 3.9.3.2
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ILCAmericas
ILC Surface Processing Facility Development at ANL/FNAL
• The Joint ANL/FNAL Superconducting Surface Processing Facility (SCSPF), located at Argonne National Laboratory, is a major chemical processing facility capable of electro-polishing and buffered chemical polishing a large quantity and variety of superconducting structures.
• This BCP part of the facility is ready and going through the safety approval. It is expected to be operational end of 06.
• An initial plans has been developed for an EP facility to be build (FY06-07) at ANL/Fermilab Surface Processing Facility at ANL.
• This facility should include the knowledge of EP from the ILC Collaboration.
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ILCAmericas Cryomodule Design and Fabrication
• In FY05 Fermilab started on converting the DESY/INFN design of the ILC cryomodule (Type-III+).
• We have formed an ILC Cryomodule working group that is working towards a design of an ILC cryomodule. This design will evolve.
• The Goal is to design an improved ILC cryomodule (Type-IV) and build one at Fermilab by FY08.
High Power testing of the cavities and the fabrication of 1st ILC cryomodule with new design 2008.
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ILCAmericas
Cryomodule Fabrication Plans for an RF Unit test at ILCTA
Cryomodule 1 Cryomodule 2Cryomodule 3
DressedCavity Provided
By DESY
Cold MassBy DESY/INFN
CryomoduleAssembled at
Fermilab
March 07
Standard LengthCavity Purchased
By Fermilab
BCP & VTAt Cornell
EP & VTAt Jlab
Cold MassFrom ZanonBy Fermilab
Dressed and HTAt Fermilab
Dec 07 Mid 08
ILC LengthCavity Purchased
By Fermilab (AES/Jlab)
BCP & VTIn USA
EP & VTIn USA
Dressed New Design and HT
At Fermilab
Cold Mass Type-IVFrom US Company
By Fermilab
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ILCAmericas
1st US Assembled Cryomodule: Fermilab, DESY and INFN
• DESY will send Fermilab eight 9-Cell 1.3 GHz dressed and horizontally tested cavities. – The present schedule for the delivery of these 8 cavities is around end
of 2006. DESY will attempt to advance this schedule.
• DESY and INFN have ordered two cold masses for Type-III cryomodules from Zanon. – DESY will send one of these cold masses to Fermilab for the 1st
cryomodule assembly at Fermilab. – It is expected that this cold mass will be available about Sept.-Oct.
2006.
• Some parts for the 1.3 GHz cryomodule are not provided by Zanon but rather by INFN. – It was agreed that INFN will send these associated parts to Fermilab
and provide parts needed for a 3rd cold mass. – INFN-DESY will also send the assembly documentation to Fermilab.
• Fermilab will work to achieve the earliest possible delivery date for the DESY four cavity 3.9 GHz cryomodule. This is currently expected to be early in 2007.
![Page 23: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/23.jpg)
ILCAmericas ILC Cryomodule Design Considerations
• Move quad package to middle of cryomodule to achieve better support and alignment.
• Shorten cavity-to-cavity interconnect and simplify for ease of fabrication and cost reduction. Possible superconducting joint.
• Overall improved packing factor.
• Minimize direct heat load to cavity through MC.
• Simplify the assembly procedure.
• MLI redesign to reduce hands-on labor costs.
• More robust design to survive shipping.
• Reliability of tuner motors in cold operation.
• Etc. (we’ve heard many suggestions)
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ILCAmericas ILC Cryomodule: Conceptual Model
![Page 25: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/25.jpg)
ILCAmericas
Increasediameter beyond X-FEL
Increasediameter beyond X-FEL
Review 2-phase pipe size and effect of slope
Change in Cryogenic Distribution
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ILCAmericas
ILC Cavity Spacing, Dimensions with Blade Tuner
Blade Tuner
35068mm1036.2 mm
Active length = 1036.2 mm x 24 cavities = 24868.6 mm
Packing Factor = 24868.6 / 35068 = 0.71
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ILCAmericas 1st Cryomodule Assembly Plans
• Cavity String Assembly Procedures & Fixtures Learning at DESY (February 20 –March 3)
– A draft traveler was written during this visit. It is currently being reviewed by Axel Matheisen for comments.
– Tooling & Fixturing used to assemble the cavity string were identified. Drawing were brought back to Fermilab.
– Assembly sketches, movies and took a lot of pictures and notes.
• Cryomodule #6 Assembly Procedures Learning at DESY (May-June 06)
• CAF Infrastructure ready & operational: May-June 06– MP9 Clean Room installation finished– Cold Mass and Vacuum Vessel Assembly Fixtures received at Fermilab.– Cavity String Assembly Fixtures are being fabricated to be installed
• Assemble 1st Cryomodule (4 months): Start date depends when we receive the kit from DESY
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ILCAmericas
Cavity and Cryomodule Assembly Fixtures
![Page 29: ILC Americas Cavity and Cryomodule R&D Shekhar Mishra ILC Program Fermilab Talk presented at DOE Annual Program Review Breakout Sessions – Wednesday, May.](https://reader035.fdocuments.in/reader035/viewer/2022062519/5697c0281a28abf838cd6acd/html5/thumbnails/29.jpg)
ILCAmericas FY07 Plans: Cavities & Cryomodule
• The FY07 plan of the ART will be the continuation of the plan we are undertaking in FY07.
• Cavity Fabrication– ILC Design– New Shape (LL and RE)– Fine, Large and Single Crystal– R&D on material, fabrication etc– 3.9 GHz deflecting cavity design and fabrication
• Cavity Processing and Vertical Testing– BCP, EP and Vertical Testing at Cornell– BCP, EP and Vertical Testing at Jlab– BCP, EP and Vertical Testing at FNAL/ANL (New Facility)– R&D on surface treatment
• Cryomodule Design and Fabrication– Type III+ Fabrication– Type IV Design
• US Industrial involvement in Cavity and Cryomodule Design and Fabrication
• Enhanced University participation in ILC R&D
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ILCAmericas Summary
• US-ILC Main Linac: Cavity and Cryomodule R&D program is established to address the key technology issues.– Cavity Gradient– ILC Cryomodule design and fabrication
• R&D is focused on the Baseline design of the cavity and cryomodule.
• We are also working on alternate design for Cavity and material.
• We are upgrading existing infrastructure at US laboratories to cost effectively advance the R&D program on a ambitious schedule.
• We are developing infrastructure at Fermilab for cavity processing and testing and fabrication of cryomodule.
• We are leading the ILC effort in the ILC Cryomodule design.
• We are working with US industry in fabrication.
• We are also working with US industry in ILC Cost Study.
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ILCAmericas
Could lab really spend the Money Faster on ILC than its currently funded?
• Yes, Yes and Yes• Fermilab has qualified scientists and engineers who wants to
work on ILC.• We continue to defer investment that would be needed for more
focused R&D.– Cavity R&D: (This is the highest R&D priority for ILC-GDE)
• Niobium • More cavities fabrication at industry. We should fabricate enough to saturate
the pipeline at existing and upcoming processing facilities. • Electron Beam Welding• Surface Processing: We need a pre-production BCP, EP and HPR system at
Fermilab• Vendor development
– Cavity Tuning Device ( A copy of DESY Design)– Vertical testing temperature study– Cryomodule Testing– 10 MWatt Klystron– Cryogenic plant– Industrial fabrication
• US industries could fabricate an RF unit using laboratory infrastructure.
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ILCAmericas FTE in ILC R&D at Fermilab: FY06 and FY07