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Dmitry Gudkov BE/RF/SR 02 December 2009

Mechanical design of TD24 11Ghz Damped Sealed Accelerating Structure (based on KEK/SLAC design documentation). Dmitry Gudkov BE/RF/SR 02 December 2009. Product Elements 1. Accelerating elements. Vacuum and interface elements. Cooling system elements. Tuning system elements.

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Dmitry Gudkov BE/RF/SR 02 December 2009

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  1. Mechanical design of TD24 11Ghz Damped Sealed Accelerating Structure(based on KEK/SLAC design documentation) Dmitry Gudkov BE/RF/SR 02 December 2009

  2. Product Elements 1 Accelerating elements Vacuum and interface elements Cooling system elements Tuning system elements

  3. Product Elements 2 Output Ring Cell Regular Cells Matching Iris A Matching Iris B Input Ring Cell Coupler Assembly With WG90 Flanges Beam Pipe Fixed Vacuum Flange Rotatable Vacuum Flange

  4. Regular Cell Disk Mechanical Design Min. gap = 0.005 mm (KEK/SLAC – 0.01 mm) Max. gap = 0.0125 mm (KEK/SLAC – 0.04 mm) Interlocking system of disks position Reference for assembly – B (Ø74±0.0025)

  5. Assembly Sequence • Bonding of all cells of the accelerating structure : Output Ring Cell Matching Iris B Regular Cells Pressure: 60PSI = = 60 x 6 894,75729 ≈ 415 kPa Temperature: 1035 °C Matching Iris A Photo by Juwen Wang (SLAC) Input Ring Cell

  6. Assembly Sequence (continuation) Coupler Cover • Coupler Subassembly: • Brazing of two parts of • the coupler using • brazing shims: • Brazing alloy: Au-Cu 25/75 • Temperature: 1045 ̊ C Brazing Shim Coupler Body Machining brazed assembly for installation of the vacuum flanges: Photo by SLAC Brazing alloy: Au-Cu 30/70 Temperature: 1035 ̊ C Brazing vacuum flanges:

  7. Assembly Sequence (continuation) Assembly of cooling block, caps, tubes: 4 x Photo by SLAC Brazing alloy: Au-Cu 25/75 Temperature: 1045 ̊ C 7/14

  8. Assembly Sequence (continuation) Brazing 1 1 x Beam Pipe 2 x Coupler Assembly Bonded Stack 4 x Cooling Block Assembly Photo by SLAC 104 x Tuning Studs Au/Cu Alloy: 35/65 Brazing temperature: 1020º C 8/14

  9. Assembly Sequence (continuation) Brazing 2: adding second beam pipe Photo by SLAC Au/Cu Alloy: 50/50 Brazing temperature: 979-983º C 9/14

  10. Assembly Sequence (continuation) TIG WELDING* Photo by SLAC * - Tungsten inert gas welding 10/14

  11. Tuning System Stud Hummer Guide Tube 11/14

  12. Tuning System Brazing 1st step: pushing studs to the tuning hole using special stainless steel pin 2nd step: fastening by wire and special ceramic pins 12/14

  13. Brazing material for tuning stud brazing 1st option: brazing wire ø0.5 mm: 2nd option: Nickel and then Silver plating of the studs: 3rd option: brazing material inside the stud: This plating becomes brazing material. 13/14

  14. The End Thanks for your attention! • Used materials: • SLAC Work Status for the CLIC High Gradient Accelerator Structure R&D, Juwen Wang, CLIC WS 09 • CERN production methods, Germana Riddone, CLIC WS 09 • Mechanical design of PSI-XFEL X-band structure, D. Gudkov • KEK, SLAC Accelerating structure documentation • CERN Accelerating structure documentation • Thanks to: • Germana Riddone • Alexander Samoshkin • Said Atieh • Juwen Wang • Riccardo Zennaro • Alexey Grudiev 14/14

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