Preliminary Design of Nb 3 Sn Quadrupoles for FCC-hh M.
Karppinen CERN TE-MSC
Slide 2
Outline Specs used for this initial study IR Quadrupole Strong
IR Quad based on QXF IR Quad meeting the spec Main Quadrupole Next
steps
Slide 3
Specs from L. Bottura (Aug -14) B / G (T) / (T/m) B peak (T)
dB/dt (mT/s) Bore (mm) Length (units x m) FCC MB1616.816404578 x
14.3 MQ37510 40762 x 6.6 QX20012.5 90 Optics ? D11213 604x2 x 12
D21010.5 604x3 x 10 Booster in the FCC MB1.122504578 x 14.3
injector in the LHC MB55.2520501232 x 14.3 injector in the SPS
MB1212.510050892 x 4.7 M. Karppinen CERN TE-MSC
Slide 4
Strong IR Quad based on QXF FCC will require large number of
challenging magnets based on Nb 3 Sn-technology that will require
industrial production CERN have long experience with industrially
built accelerator magnets (design, part procurement, production
methods & tools, acceptance tests) 11 T Dipole is the first Nb
3 Sn magnet that has been designed from the beginning to be
compatible with accelerator quality requirements. The design
concept and certain new features can be applied on Nb 3 Sn
quadrupole HL-LHC IR-Quad QXF has been extensively optimized making
it a good reference for comparing with the alternative design
concept Demonstrator magnet based on QXF coil design could be made
using primarily existing tooling and with modest investment on
certain magnet components (collars, yoke lams, shells, end plates)
Possible plan-B for HL-LHC in case the present base-line design
fails meeting the performance criteria M. Karppinen CERN
TE-MSC
Slide 5
HF Quadrupole Design Concept Industrial accelerator quality
design: Collared coils, fine-blanked/precision punched SS collars
Iron yoke, fine-blanked/precision punched SS collars Welded SS
outer shell Well known assembly methods and tooling: Dipole-type
collars, assembly in (existing) dipole collaring press H/V split
yoke, assembly in (existing) dipole yoking press 11 T Dipole
experience: Pole loading principle adapted to quadrupole coils Coil
pre-compression applied in controlled and easily tunable fashion
during collaring Welded outer shell with acceptable and achievable
stress levels Very rigid and static mechanical structure with
closed yoke gap M. Karppinen CERN TE-MSC
Slide 6
Collared QXF Magnet Conceptual design study based on QXF coils
150 mm coil aperture 140 T/m @ 17.46 kA (150 T/m @18.8 kA) poles
are not part of the coil (not potted together) additional outer
layer wedge & SS loading plate Dipole type collars (IR 115 mm,
OR 160 mm) Horizontally split laminated yoke, OD 600 mm Welded
stainless steel outer shell (15 mm) M. Karppinen CERN TE-MSC
Slide 7
18.8 kA & 150 T/m M. Karppinen CERN TE-MSC
Slide 8
Modified QXF Coil Filler wedge Loading Plate St. steel t = 2 mm
Insulation t = 0.2 mm M. Karppinen CERN TE-MSC
Slide 9
Collared Coil 12 St.steel keys 10x12 mm R115 R160 Ti-alloy pole
wedge Stress relieve notch Shim M. Karppinen CERN TE-MSC
Slide 10
Radial deformation after collaring => Horizontal split yoke
0.2 mm 0.05 mm M. Karppinen CERN TE-MSC
Slide 11
Yoke & Shell Al-gap controller R160.4 R300 Stainless steel
Shell t = 15 mm Weld shrinkage 0.84 mm Taper 0..0.2 mm 81.75 M.
Karppinen CERN TE-MSC
Slide 12
Azimuthal Coil Stress Collaring Press After Collaring After
Yoke Assembly 293 K After Cooldown 1.9 K 17.4 kA 140 T/m 18.8 kA
150 T/m MPa M. Karppinen CERN TE-MSC
Slide 13
Slide 14
Slide 15
Slide 16
Slide 17
Collar Stress (Von Mises) M. Karppinen CERN TE-MSC After
collaring After yoke assembly At 293 K After cooldown at 1.9 K At
1.9 K, 150 T/m
Slide 18
Yoke & Gap-controller After Yoke Assembly 293 K After
Cooldown 1.9 K 18.8 kA 150 T/m Gap-controller defines the yoke gap
during yoke assembly Yoke gap is closed after cooldown and remains
firmly closed up to 150 T/m Azim. Shell Stress after Yoke assembly
MPa M. Karppinen CERN TE-MSC
Slide 19
Summary of QXF based IR Quad Coil stress between 0 and 150 MPa
at all times. Coil stress distribution can be customized to
counter-balance the magnetic forces. Very rigid collars provide the
pre-stress in controllable way with only small elliptic deformation
Tapered yoke mid-plane gap and gap-controller provide static and
very rigid structure from CM assembly down to 1.9 K and 150 T/m 15
mm SS shell stress at acceptable levels at all stages using
achievable welding shrinkage Rigid structure maintains very well
the quadrupole symmetry. Assembly possible with existing tools and
easily available components. Scale-up straight forward, once long
coils available. M. Karppinen CERN TE-MSC
Slide 20
IR Quad Demonstrator magnet Use QXF coils: First end spacer on
IL/OL with slot, wind & cure with existing tooling After binder
curing add filler wedge and reaction pole React with existing QXF
reaction tool Add loading plates and impregnation pole Vacuum
impregnate with existing QXF tooling Introduce pole wedges, ground
insulation, and collaring shoe Collar assembly in existing
collaring press with new press tool Yoke and outer shell assembly
in 180 yoking press with new end plates Protection heaters can be
identical to QXF Instrumentation can be identical to QXF 2 years
can be considered realistic time-scale including part procurement
and manufacturing time with appropriate human resources M.
Karppinen CERN TE-MSC
Slide 21
QX Specs B / G (T) / (T/m) B peak (T) dB/dt (mT/s) Bore (mm)
Length (units x m) FCC MB1616.816404578 x 14.3 MQ37510 40762 x 6.6
QX20012.5 90 Optics ? D11213 604x2 x 12 D21010.5 604x3 x 10 Booster
in the FCC MB1.122504578 x 14.3 injector in the LHC MB55.2520501232
x 14.3 injector in the SPS MB1212.510050892 x 4.7 M. Karppinen CERN
TE-MSC
Slide 22
QX Cable OST RRP-108/127 M. Karppinen CERN TE-MSC
Slide 23
QX Coil X-section Aperture 90 mm 36 turns (IL 16, OL 20) No
grading I-L insulation 0.7 mm Mid-plane insul. 0.2 mm FQ r30mm (200
T/m): b6 = 0.8 units b10 = 0.18 unit L diff = 4.26 mH/m E mag = 401
kJ/m Field errors with iron saturation at 200 T/m M. Karppinen CERN
TE-MSC
Slide 24
QX Load-Line @1.9 K G(13.4 kA) = 200 T/m Bp(13.4 kA) = 10 T
wp(13.4 kA) = 77 % wp(13.4 kA, 4.3K) = 83 % T marg = 5.4 K Bc = 13
T M. Karppinen CERN TE-MSC
Slide 25
QX Magnet X-Section Yoke OD 275 mm ID 103.5 mm M. Karppinen
CERN TE-MSC
Slide 26
FCC IR Quadrupole Parameters M. Karppinen CERN TE-MSC
Slide 27
QX Mechanical Structure Coil features Removable Ti-alloy poles
(not glued in) Additional outer layer wedge & stainless steel
loading plate. Wedges made of ODS alloy. S2-glass-Mica cable
insulation Dipole type collars (IR 75.4 mm, OR 103.5 mm)
Horizontally split laminated yoke, OD 550 mm Al-gap controller
Welded stainless steel outer shell (15 mm) M. Karppinen CERN
TE-MSC
Slide 28
QX Collared Coil Ti-alloy pole wedge Coil assembly 12 Stress
relieve notch Shim R74.4 R103.5 M. Karppinen CERN TE-MSC
Slide 29
QX Yoke & Shell Al-gap controller R103.9 R275 Stainless
steel Shell t = 15 mm Weld shrinkage 0.84 mm Taper 0..0.2 mm 81.75
M. Karppinen CERN TE-MSC
Slide 30
QX Azimuthal Coil Stress MPa Collaring Press After Collaring
After Yoke Assembly 293 K After Cooldown 1.9 K 13.4 kA 200 T/m 15
kA 223 T/m M. Karppinen CERN TE-MSC
Slide 31
QX Summary Magnetic design based on 13.7 mm Nb3Sn cable meets
the present specification with comfortable margin The mechanical
design, further development of the 11 T Dipole pole-loading
concept, provides very stable support structure for the coils The
design is adapted for industrial production based on existing
production methods and tools M. Karppinen CERN TE-MSC
Slide 32
MQ Specs B / G (T) / (T/m) B peak (T) dB/dt (mT/s) Bore (mm)
Length (units x m) FCC MB1616.816404578 x 14.3 MQ37510 40762 x 6.6
QX20012.5 90 Optics ? D11213 604x2 x 12 D21010.5 604x3 x 10 Booster
in the FCC MB1.122504578 x 14.3 injector in the LHC MB55.2520501232
x 14.3 injector in the SPS MB1212.510050892 x 4.7 M. Karppinen CERN
TE-MSC
Slide 33
MQ Cable OST RRP-108/127 M. Karppinen CERN TE-MSC
Slide 34
MQ Coil X-section Aperture 40 mm 18 turns (IL 7, OL 11) No
grading I-L insulation 0.7 mm FQ r10mm (383 T/m): B6 = 0.013 units
B10 = 0.00 unit B14 = 0.07 units L diff = 1.96 mH/m E mag = 251
kJ/m Field errors with iron saturation at 383 T/m M. Karppinen CERN
TE-MSC
Slide 35
MQ Load-Line @1.9 K G(16 kA) = 383 T/m Bp(16 kA) = 8.6 T wp(16
kA) = 75 % T marg = 5.9 K Bc = 11.6 T M. Karppinen CERN TE-MSC
Slide 36
MQ Magnet X-Section Yoke OD 150.8 mm ID 550 mm Beam separation
250 mm Magnetically very similar down to 180 mm separation
Mechanical concept based on dipole collars M. Karppinen CERN
TE-MSC
Slide 37
FCC Main Quadrupole Parameters M. Karppinen CERN TE-MSC
Slide 38
Next steps.. Engineering design of IR Quad Demonstrator based
on QXF coils (DAI raised) Demonstrator magnet construction &
test MQ mechanical design Design iteration based on more serious
specs Final design Model magnet program Prototype magnets Series
production M. Karppinen CERN TE-MSC