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11 T Dipole Experience

11 T Dipole Experience. M. Karppinen CERN TE-MSC On behalf of CERN-FNAL project teams. The HiLumi LHC Design Study (a sub-system of HL-LHC) is co-funded by the European Commission within the Framework Programme 7 Capacities Specific Programme , Grant Agreement 284404. .

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11 T Dipole Experience

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  1. 11 T Dipole Experience M. Karppinen CERN TE-MSC On behalf of CERN-FNAL project teams The HiLumi LHC Design Study (a sub-system of HL-LHC) is co-funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404.

  2. 11 T Dipole for DSUpgrade • Create space for additional collimators by replacing 8.33 T MB with 11 T Nb3Sn dipoles compatible with LHC lattice and main systems. • 119 Tm @ 11.85 kA (in series with MB) • LS2 : IR-2 • 2 MB => 4 x 5.5 m CM + spares • LS3 : IR-1,5 and Point-3,7 • 4 x 4 MB => 32 x 5.5 m CM + spares • 180 x 5.5-m-long Nb3Sn coils • 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 5.5 m Nb3Sn 0.8m Collim. 5.5 m Nb3Sn M. Karppinen CERN TE-MSC

  3. 11 T Dipole Design Features 11.25 T at 11.85 kA with 20% margin at 1.9 K 60 mm bore and straight 5.5-m-long coldmass 6-block coil design, 2 layers, 56 turns (IL 22, OL 34), no internal splice Separate collared coils, 2-in-1 laminated iron yoke with vertical split, welded stainless steel outer shell M. Karppinen CERN TE-MSC

  4. 11 T Model Dipole Magnetic Parameters M. Karppinen CERN TE-MSC

  5. Mechanical Design Concepts • Coil stress <150 MPa at all times up to 12 T design field • Yoke gap closed at RT and remain closed up to 12 T Loading plate Shim Filler wedge Pole wedge Pole loading design Integrated pole design CERN FNAL M. Karppinen CERN TE-MSC

  6. CERN 11 T Dipole Coil Loading plate 2 mm 316LN SLS (Selective Laser Sintering) End Spacers with “springy legs” Courtesy of D. Mitchell, FNAL ODS (Oxide Dispersion Strengthened) Cu-alloy Wedges Braided 11-TEX S2-glass on “open-C” Mica sleeve 14.85 Ø0.7 OST RRP-108/127 M. Karppinen CERN TE-MSC

  7. MBHSP01 Quench Performance • FNAL 2 m single-aperture model #1 • RRP-108/127 strand, no core • Bmax=10.4 T at 1.9 K and 50 A/s (78% of SSL) • long training • irregular ramp rate dependence • Conductor degradation in coil OL mid-plane blocks and leads • lead damage during reaction - confirmed by autopsy A.V. Zlobin et al., ASC2012, Sept 2012 Quench history Ramp rate dependence M. Karppinen CERN TE-MSC

  8. MBHSP02 Quench Performance • FNAL 1 m single aperture model #2 • RRP-150/169 strand, 25 µm SS core • Improved quench performance • Bmax= 11.7 T – 97.5% of design field B=12 T (78% of SSL at 1.9 K) • Field quality meets the present requirements • Issues to be addressed • Long training • Steady state B0 = 10.5..10.7 T @1.9K • Origin of conductor degradation in OL mid-plane blocks in coil fabrication or assembly process? Courtesy of G. Chlachidze, FNAL Magnet training Ramp rate dependence M. Karppinen CERN TE-MSC

  9. MBHSM01 Mirror Magnet M. Karppinen CERN TE-MSC

  10. MBHSM01 Quench Training Highest quench current at 4.5 K: 12.9 kA (92-100) % of SSL at 1.9 K: 14.1 kA (89-97) % of SSL About 4% degradation observed at 4.5 K after the 1.9 K training SSL at 1.9 K SSL at 4.5 K 4.5 K 1.9 K 4.5 K Courtesy of G. Chlachidze, FNAL M. Karppinen CERN TE-MSC

  11. Lessons: Coil Parts • Nb3Sn Rutherford cable • Stainless steel core reduces eddy current effects • Limited compaction reduces mechanical stability • Winding tooling and process development • Braiding S2-glass over Mica-sleeve works well • End parts • SLS cost effective, flexible, and fast way of producing fully functional parts • 3-5 iterations required to get the shapes right, all manual modifications shall be minimised • Rigid metallic parts need features to make the “legs” flexible (“springy legs”, “accordeon”,..) • Dielectric coatings to develop: reactor paint, sputtering, plasma coating, .. • Epoxy-glass saddles (electrical insulation, softer for cable tails/splice, axial loading) • ODS wedges to minimise plastic deformation and distortion of the coil geometry M. Karppinen CERN TE-MSC

  12. Lessons: Coil Fabrication • Min 3 Practice coils: Cu-cable, 2 X Nb3Sn • Mirror test to qualify coil technology • Tooling design • Modular tooling for easy scale-up • Understand (= measure) coil dimensional changes • Tight manufacturing tolerances require high precision quality control • Material selection and heat treatments (reaction tool) • First design the impregnation tool then reaction tool • Coil inspection: • E-modulus risky to measure • High modulus (wrt. Nb-Ti) means tight tolerances and require accurate dimensional control with CMM • Assembly parameter definition based on CMM data can be tricky.. M. Karppinen CERN TE-MSC

  13. To Develop: Heaters & Splicing • Outer layer heaters • Heaters and V-tap wiring integrated in polymidesandwich (“trace”) made as PCB • may not be enough to guarantee safe operation with redundancy • Inner layer “trace” difficult to bond reliably • Inter-layer heaters • Very efficient heat transfer to coils • Reaction resistant glass-Mica-St.St-Mica-glass sandwich • “Conventional” heaters with I-L splice • Inter-layer splice (within the coil i.e. high field) • Bring inner layer lead radially out and splice • Nb3Sn bridge (MSUT concept) • HTS bridge M. Karppinen CERN TE-MSC

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