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Summary of WG2: Design and Fabrication of Cavities and Cryomodules

This summary highlights the activities and infrastructure overview of the XFEL project, low beta design issues, and pressure vessel codes for cavity and cryomodule fabrication. It also discusses the progress in infrastructure construction and procurement of equipment at various vendors, as well as the testing and finalization of XFEL cavity prototypes. The importance of power coupler cleaning, pressure vessel certification, and cryomodule design are also emphasized.

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Summary of WG2: Design and Fabrication of Cavities and Cryomodules

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  1. Summary of WG2: Design and Fabrication of Cavities and Cryomodules A total of 25 talks were presented - XFEL Activities - Infrastructure overview - Coupler business - PED pressure vessel codes - Low beta design issues for cavities and modules It is impossible to show every highlight in the summary. Please excuse us if one or the other highlight is not mentioned or missing. Its hard to extract all essential information and highlights for a short presentation summary ! TTC - Milano WG-2 Summary

  2. TTC - Milano WG-2 Summary

  3. Preparation for XFEL/1 • The infrastructure layout for the cavity fabrication plants at vendors (Zanon and RI), and for the cryomodule assembly plant at CEA-Saclay • Construction of the cavity plants, procurement of equipments (clean room, furnace, BCP, etc...) are underway. • Warm RF test/tuning machines provided by DESY. • CEA plant is in commissioning phase with 2 proto-XFEL modules • First XFEL cavities are expected by mid-2012. • Nb and NbTi material is procured by DESY to 4 vendors worldwide. TTC - Milano WG-2 Summary

  4. Preparation for XFEL/2 • The FLASH 3.9 GHz module built by FNAL is in operation at nominal gradient, and has already generated short bunches. • Success story • Starting from that, now the construction of the XFEL 3.9 GHz cavity prototypes and of the 8 cavity module, is under the responsibility of INFN-Milano. • Prototypes are close to testing stage and the XFEL 3H system design is being finalized and on the way to procurement. TTC - Milano WG-2 Summary

  5. TTC - Milano WG-2 Summary

  6. Infrastructures • CERN plans to refurbish existing infrastructure for various projects including continuing SPL cavity and cryomodule development work (also LHC/ISOLDE/CLIC) • University of Wuppertal, Germany • DC Field Emission Scanning Microscopy on Nb Samples • High Resolution SEM/EDX for Field Emitter Identification • Surface Roughness Measurements with OP/AFM on Nb • “New” Infrastructure at Saclay (not only XFEL, long range roadmap (Spiral2, IFMIF, ESS…, R&D topics) • Refurbishment/upgrade of existing infrastructures at DESY/JLAB (TEDF)/KEK (Pilot Plant) TTC - Milano WG-2 Summary

  7. TTC - Milano WG-2 Summary

  8. Mircea Stirbet, Power Coupler cleaning • SNS Power coupler as an example : • The FPC cleaning should start at the design stage • Adequate infrastructure • Trained personnel • The importance of meticulously cleaning the power coupler before it is installed on a clean SRF cavity is widely accepted A B A- FPC initial concept welded outer conductor impact on cleaning!!! B - FPC prototype independent outer conductor Everybody takes the QC very seriously! BUT….

  9. Is our inspection sufficient? D. Kostin, M. Champion But: we see unexpected damage after operation (not found during acceptance QC)

  10. TTC - Milano WG-2 Summary

  11. WG 2 Part Pressure vessel certification and Cryomodule Design contributed talks Pressure vessels codes 3 different approaches presented to find local solutions KEKDefinition of pressure vessel = Cavity without 2 Phase line  simplified rules FNAL adopted to legal Department of Energy rules, Lab internal codes, and regulations DESY Co working with the notified body Next stage would be to address the international exchange of components concerning PV requirements TTC - Milano WG-2 Summary

  12. KEK Definition of pressure vessel Advantages with the Category of Ordinal Device at PV < 0.004 • Process and inspection with HP code simplified • Material mechanical evaluation prior to production process required, • HP code test (Pressure, and leak test) only required in the completion process, • Subject for further investigation • If the 2–phase pipe to be included in the cavity category or to be included in the cryomodule? • Can we convert material at the boundary; Ti to SUS (including joint). Akira Yamamoto and Eiji Kako TTC - Milano WG-2 Summary

  13. Arkadi Klebaner  TTC - Milano WG-2 Summary

  14. PED handling of the DESY/ XFEL cavities Way for DESY to cover PED regulations • - Operational experiences over 15 years • - About 160 cavities build  long term experiences in cold operation • - Experiences on pressure + crash test @ 2K on Cavity C 26 and Module 3* • - Traceability of drawings, fabrication, materials and preparation • DESY is defined as the manufacturer • - Fabricate a “test piece” (pre production welding test acc. to ISO 15613) • for destructive tests • - Manufacture n Cavities with notified body on place and do non destructive • testing on them (DCV - RCV cavities for XFEL Cavity production) • - Set up PMA material for materials (as in use) and follow this PMA strictly! • (PMA= Particular Material Appraisal Acc. PED(97/23/EC) annex I, Sec 4.2) • - Perform a pressure test on completed cavity for each cavity build TTC - Milano WG-2 Summary

  15. ERL cryomodule systems • KEK -- construction of cERL Injector Cryomodule. • Work includes development and testing of prototype cavities, input couplers, HOM couplers, and a slide-jack frequency tuner. These components have been integrated into a cryomodule design, and a cryostat is under fabrication. • STFC -- An international collaboration was initiated in early 2006 with the goal to fabricate a new CW ERL cryomodule and validate with beam, dimensioned to fit on ALICE. • Work includes cavity devepment and testing, tuner (Saclay type-II) modification and development, input coupler and HOM absorber development and testing, and development of a cryogenic heat exchanger system for providing new levels of thermal shield cooling. TTC - Milano WG-2 Summary

  16. ERL cryomodule systems (continued) • Cornell -- An ERL injector prototype has been developed, fabricated, and is currently under commissioning. • Design work on the main linac cryomodule has started. Work includes Cavity support and alignment, magnetic shielding for high Q0, considerations for cryogenics and thermal shield and thermal intercept cooling with very high heat loads, and microphonics. Design features were compared to FLASH/XFEL modules. • JINR -- In 2006, JINR (Dubna, Russia), VNIIEF (Sarov, Russia), INFN (Pisa, Italy), and FNAL (Batavia, USA) established a collaboration upon the initiative of the JINR and started joint activities on the ILC. • Work includes R&D on bimetallic transitions, cavity interconnect development, precision long-distance laser metrology, and SRF cavity work. In 2007 the JINR officially joined the ILC Project and proposed the Dubna region for the ILC location. TTC - Milano WG-2 Summary

  17. TTC - Milano WG-2 Summary

  18. Low Beta design issues • IFMIF SC HWR Cryomodule Development F.ORSINI (CEA) • Impressive CW beam specs (125 mA D+) • Cavity package/cryom. using novel solutions (e.g. tuner) • Unfortunately cavity not yet completely to specs, interesting to hear at next TTC meeting • Low beta cryomodule developments at FNAL Tom Nicol (FNAL) • Engineering towards prototyping of Project X modules • Main project choices • SC linac since 2.5 MeV! • Choice of “fine segmentation” of modules • 2 K operation (even at the moderate frequency of the low energy end) TTC - Milano WG-2 Summary

  19. Low Beta design issues • Plans for CERN SPL Test Cryomodule Wolfgang Weingarten (CERN) • Design of a short 4-cavity b=1 cryomodule for SPL • Still in conceptual stage in many areas, moving to engineering • Main motivation is RF-test stand for cavities fed by single or multiple RF source (SPL design) • Cavity is supported by coupler • Spiral 2 Cavities and Cryomodule Tests Guillaume Olry (IPN) • Very good VT performances according to specs for gradient and field emission onset • After 2 module assemblies performance deteriorated • Evidence of spots and scratches on cavity and antenna surfaces after inspection • Please share the findings and conclusions at next TTC meeting! TTC - Milano WG-2 Summary

  20. Conclusions • SRF technology is gaining maturity in a diversified environment • We would like to hear more about cavity and cryomodule design, test, and operational experience at the next TTC • All types of cavities and cryomodules -- e-, proton/H-, heavy ion, ERL • Various design concepts • Assembly and operational experience TTC - Milano WG-2 Summary

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