Magnet R&D Plan for 2011-2013

1. BNL - FNAL - LBNL - SLAC Magnet R&D Plan for 2011-2013 GianLuca Sabbi LARP Collaboration Meeting 15 SLAC, November 1st, 2010

2. Outline • Magnet R&D Program components • Progress since CM14 • Preparing for the 2013 technology selection • Ongoing activities (Materials, LQ, HQ) • New activities (LHQ, HL-LHC Design study) • MS parallel session organization • Working group participants/agenda • Summary

3. Program Components • Materials R&D: • Strand specification and procurement • Cable fabrication, insulation and qualification • Heat treatment optimization • Technology development with Racetrack Coils: • Subscale Quadrupole (SQ) • Long Racetrack (LR) • Cos 2q Quadrupoles with 90 mm aperture: • Technology Quadrupole (TQ) • Long Quadrupole (LQ) • Cos 2q Quadrupoles with 120 mm aperture: • High-Field Quadrupole (HQ) • Long High-Field Quadrupole (LHQ) Ongoing Completed Completed ~75% ~30% Starting

4. Magnet Development Chart Completed Ongoing Starting

5. Magnet Series SQ SM TQS LQS-4m LR HQ TQC

6. Magnet Tests in the last 12 months • Dec. 2009 LQS01a (first Long Quadrupole) - FNAL • Achieved target gradient of 200 T/m • Dec. 2009 TQS03c (high stress) - CERN • 88% SSL w/200 MPa average coil stress • Feb. 2010 TQS03e (cycling) - CERN • No degradation after 1000 cycles • ------------------------------------------------------------------------------------------- CM14 • May 2010 HQS01a (first High-Field Quadrupole) - LBNL • >155 T/m @4.5K, already above NbTi limit @1.9K • June 2010 HQS01b (revised coil-structure shims) - LBNL • First Quench >150 T/m (78%); insulation failure • July 2010 LQS01b (revised coil-structure shims) - FNAL • Rapid training to >220 T/m @4.5K; retained at 1.9K • Oct. 2010 HQS0c (two new coils) - LBNL • Insulation OK, but lower quench levels (~135 T/m)

7. Next Milestone: 2013 Technology Selection • Consensus within LARP/DOE and with CERN on the basic strategy: • Aperture: build on existing platforms (90 mm & 120 mm) • LQ for reproducibility, length effects, process optimization • Short HQ models for high field and accelerator quality • Long HQ (LHQ) to demonstrate scale-up of 120 mm design • CERN will proceed with 120 mm aperture, 2m long NbTi models • Direct performance comparison will be a key input for TS • Several critical questions need to be addressed: • Accelerator quality targets and platform (1-m or 2-m models) • LHQ length and strategy for scale-up to production length • R&D coordination with CERN, EU, Japan programs • Need official protocol to guide design decisions & R&D priorities • A CERN-US working group has been formed to define it

8. Materials Procurement and R&D • Conductor Procurement • Conductor availability still limiting cable R&D/production • Significant orders placed in FY10 – all 108/127, Ta-doped • Expect strand inventory ok after 2/2011, cable to follow • Rapidly increasing demand (ITER+HEP) is an issue • Cable insulation • Fiber Innovation S-glass sleeve was used in all LARP magnets • FI production line has been discontinued • Several options are being investigated: • For R&D: alternative vendors/materials for sleeve • For production: direct braiding or tape wrap • Need to fully qualify one or more alternative solutions

9. Cable R&D and Production • Significant and positive experience in LARP: TQ (30 UL, 65 m); LQ (18 UL, 200 m); LR (3 UL, 200 m); HQ (14 UL, 100 m) • Good results with 2-step process: first pass, anneal and re-roll • However, labor intensive and difficult to integrate cores • Several R&D runs were carried out in FY-2010: • Two-pass Ti-doped 108/127 (qualify for future use) - coil 11 • One-pass w/pre-annealed wire (lower cost, SS core) - coil 13 • One-pass w/SS core (control of dynamic effects) - coil 12 • These cables are being used/tested in HQ 1-meter coils • Need to converge on a final design for HQ and LHQ

10. LQ Status and Next Steps • Fully reproduce performance of the TQ short models • Higher gradient (220 T/m in TQS02, 240 T/m in TQS03) • Fast training (plateau in 5-10 quenches, no retraining) • Clear progress already demonstrated in LQS01b • Systematic analysis of coil length effects • Detailed modeling of the reaction process • Understand/optimize coil strain state after reaction • Design and process optimization for construction • Coil size control/reproducibility • Protection heater design, esp. for inner layer • One-side loading with 4 m keys/bladders • Cable insulation techniques for production

11. LQ Plan 2010-12

12. HQ insulation failure: Review comments • Work is now beginning to understand the causes of the failure and remedy those causes in the design or in the fabrication procedures. This effort is of course the highest priority of the LARP team and is being approached in that way. • The recent failure of HQ2 raises an urgent need to understand its origins and modify design or fabrication to remedy them. • The team is responding with urgency and effective organization to this challenge, such failures are part of R&D, and this should be seen as simply a step towards ultimate success.

13. HQ Status and Next Steps • Electrical integrity issues: • HQ01c test shows that the failure analysis and new QA is working – program can proceed by coil selection and process improvements • HQ01c test also confirms focus on coil design and fabrication • In parallel: coil design modifications for improved robustness • Short model R&D using baseline, alternative and mirror structures: • Feedback on cable/coil design and fabrication • Pre-load targets & uniformity, quench performance • Quench protection and thermal studies • Design features for production and accelerator integration • Field quality characterization and optimization • Performance verification for 2 half-length coils in one structure

14. HQ Plan 2010-12

15. Status of HQ Scale-up planning • Ongoing planning discussions by LARP magnet steering committee, Luminosity Task force, CM14, DOE Review, US-CERN WG • Decision timeline: balance long lead times with the requirement of a strong foundation from technical and programmatic standpoint • Expected magnetic length of HL-LHC IR Quads in the range of 7-10 m • Full-length quad preferred for project, half-length can be considered • Full-length models not feasible for LARP, especially on TS time scale • Converging on two options: LQ length or slightly above (4.5 m total) • Key considerations: • Infrastructure and resource/material availability • Trade-offs between length, schedule, cost, risk • Integration with APUL, DS dipole, base programs

16. HL-LHC WP 3.2 (Nb3Sn Quadrupoles) • 36 man-months over 3-4 years • Consistent with FY11 MS funding allocation (~0.8 FTE) • WBS options: MS design studies or JIRS

17. From LARP R&D to HL-LHC Construction • Assuming technology decision at the end of 2013 and installation in 2020 • 3 years for coil fabrication requires 2 production lines of full length coils • 64 full length coils required i.e. one new coil completed every ~2 weeks

18. Length considerations for the IR upgrade • HQ short sample gradient is 200 T/m @ 4.5K & 220 T/m @ 1.9K • Assume operation at 170 T/m and same basic layout as baseline LHC •  magnet length is ~7.4 m (Q1 & Q3), 6.4 m (Q2a & Q2b) • Half length elements: ~4.1 m (Q1/Q3), ~3.5 m (Q2a/b) w/10% factor • Technical comparison: • Full length elements are clearly preferred for optimal IR performance • Full length elements should be less costly for production • However, they require new infrastructure • Full length elements need to be demonstrated experimentally • This can impact the schedule and decision process • Half-length elements could be considered as a fall-back solution • Loss of efficiency is 5-15% depending on implementation

19. MS Parallel Session Organization Tuesday morning: working group meetings (3+3 sessions): • 9 (8:30) to 10:30 • A1A HQ coil, current design Helene Felice • A1B HQ structures Paolo Ferracin • A1C Medium term plans Giorgio Ambrosio • 10:50 to 12:20 • A2A HQ coil, new design Helene Felice • A2B Magnet testing Guram Chlachidze • A2C Materials Arup Ghosh Tuesday afternoon: WG reports and general discussion Check CM15 agenda in indico for meeting room and remote connection info

20. Proposed WG participants • A1A (HQ coil, current design): Helene Felice (coordinator), Rodger Bossert, Dan Cheng, Dan Dietderich, John Escallier, Ray Hafalia, Maxim Martchevskii, Fred Nobrega, Tiina Salmi, Jesse Schmalzle, Xiaorong Wang • A1B (HQ structures): Paolo Ferracin (coordinator), Mike Anerella, Dariusz Bocian, Shlomo Caspi, John Cozzolino, Paolo Ferracin, Attilio Milanese, Soren Prestemon • A1C (Medium term plans): Giorgio Ambrosio (coordinator), Arup Ghosh, Mike Lamm, GianLuca Sabbi, Bruce Strauss, Peter Wanderer, Sasha Zlobin, Ezio Todesco • A2A (HQ coil, new design): Helene Felice (coordinator), Giorgio Ambrosio, Dariusz Bocian, Rodger Bossert, Shlomo Caspi, Paolo Ferracin, Fred Nobrega, Jesse Schmalzle, Attilio Milanese • A2B (Magnet testing): Guram Chlachidze (coordinator), John Escallier, Mike Lamm, Maxim Martchevskii, Joe Muratore, Tiina Salmi, Peter Wanderer, Xiaorong Wang • A2C (Materials): Arup Ghosh (coordinator), Emanuela Barzi, Dan Cheng, Dan Dietderich, Soren Prestemon, GianLuca Sabbi, Bruce Strauss, Ezio Todesco, Sasha Zlobin

21. WG Agenda Topics (1/2) • A1B – HQ Structures • Discuss/compare design features and FEA results for the two structures (follow up from 9/24 video meeting) • Possible synergies, e.g. use of new bladders or collared coil in current structure • Options/plans for testing two coils in the same structure (to check the performance using half-length coils) • Options/plans for a test that will incorporate a pressure vessel over the aluminum shell • Heat transfer calculations and design features for improved cooling • A1C – Medium term plans • US contributions to the LHC upgrades in Magnet Systems (APUL, LARP, 11T dipoles): coordination of goals and resources • LHQ goals, schedule, effort distribution, budget envelope • Selection of a suitable length for LHQ • Field quality studies: determine if 1-m models are sufficient • LARP support of HL-LHC design study • Options for adding a winding/curing production line for HQ coils • Radiation studies

22. WG Agenda Topics (2/2) • A2A – HQ Coil, new design • Cross-section: how to adapt to new insulation thickness, adjust cable thickness to include core and to account for growth in radial coil size • Increased insulation thickness between layers and between coil and parts • Changes in end part design for better fit • Axial shift to mitigate insulation issues next to end shoes • Optimization of end field quality • Changes in the inter-layer ramp to increase the true straight section length • Schedule for implementing design changes; Target coil number for new design • A1C – Materials • Conductor characterization/QA. Protocol for verification of as-delivered strand, cable qualification, coil witness samples. Match to LQ/HQ schedule. Work plan at each lab. • Confirm cable production schedule for LQ/HQ in FY11, matched to conductor delivery and coil fabrication schedule • Status of cored cable R&D, next steps leading to integration in HQ coil fabrication • Cable insulation plan, in particular regarding evaluation and transition to new options • Cables for LHQ (consider two cases, 3.3 m coil length - same as LQ - and 4 m coil length). Assume 2 UL in FY11, 4 in FY12, 4 in FY13. Are current procurements able to sustain production, in addition to LQ/HQ? Can we get a reasonable yield from the conductor inventory, given typical strand piece length? Based on past experience, what yield can we expect taking into account production issues (crossovers, etc) Discuss/compare design features and FEA results for the two structures • A1B – Magnet testing • Test requirements for the long HQ (consider two cases, 3.3 m coil length - same as LQ - and 4 m coil length): possible facilities and required upgrades. • Large diameter probes for field quality measurements: probe fabrication, anti-cryostat/header modifications, possibility to perform measurements in LHe. • Magnet protection from shorts/ground faults • Quench Detection • Electrical QA: status, analysis etc.