Undulator System Components Status Dean Walters

1. Undulator System Components Status Dean Walters 1

2. Undulator System Components Status Components • Vacuum Components • Chamber • Quad Spool • Bellows • EVAC Flanges • Diagnostics • RFBPM • Beam Finder Wire • Beam Loss Monitor 2

3. Vacuum Chamber End bi-metal flange welding From: E Trakhtenberg G Weimerslage 3

4. Vacuum Chamber Graphical Display of Surface finish Data The average of all vacuum chambers is 14.86 mrad in Z′ and 35.14 mrad in X′, the rms of Z’ is 15.5 mrad and X’ is 36.9 mrad. Selecting the best 33 chambers yields an rms for Z’ of 13.9 mrad and X’ of 34.2 mrad. Extrusions 7, 10, 16, 28 and 35 were sacrificed to verify surface finish in the middle of the extrusions Should be Avoided Acceptable 15.5 Very Desirable From: E Trakhtenberg G Weimerslage 36.9 4

5. Quad Spool • Design • Flexible mini-bellows • Surface finish measurements of the central tube show a roughness of Sq=.18 µm • Issue with aluminum plating covering the seal face of the EVAC flange, the vendor has addressed this during the course of the production run. • Fifteen units have now been shipped • The production run is due to be complete by the end of June 5

6. Bellows Module • Initially the supplier had problems with the welding of the SST adapter to the flange. The supplier solved the problem by using the micro-TIG welding process. • All (35) units have assembled, baked, packaged, and shipped to SLAC. The last group went to SLAC on 6 June 2008 6

7. EVAC Flange System • Flange Permeability • Flanges from the manufacturer have been found to have a high (1.21) magnetic permeability. • Testing has shown that while the permeability is high it will not interfere with devices in the beamline. • Flange Sealing Experience • SLAC has started to assemble girders and has had to make vacuum seals using EVAC Flanges. • Their initial results have been good and bad. • One thing that has been seen is that the pits in the copper gaskets are thought to be a source of leaks. • ANL is now inspecting all gaskets for pits before sending to SLAC. • SLAC is experiencing what ANL went through before consistent results were achieved. • Through testing at ANL it was found that lubrication of the chain clamp is important, ANL is using Dicronite lubricate on all chains in the Undulator Vacuum System. 7

8. BFW Assembly Mounted on Adjustable Support Electrical Connectors for Wire Signals Potentiometer Pneumatic Solenoid Valve Compression Spring Positioner Air Supply Shut Off Valve Precision Screw Card Position Monitor (Limit switches) Frame Housing Alignment Fiducials Pneumatic Cylinder (Modified since) Vacuum Pump Connector (2.75” Conflat Flange) Vacuum Chamber Connection Flange (NW-50 CeFix w/Clamp) Adjustable Mounting Support Beam Port Assembly model courtesy: J. Bailey, ANL 8

9. Moving Slide Assembly (Solid Body) Electrical Connector and Feedthrough Secured to Slide Rod Kinematic Stop Top Plate Fixed to Frame (Adjustable using precision Screws) Top of Return Spring Fixed to Frame Kinematic Stop Bottom Plate Secured to Slide Block Slide Block Secured to Slide Rod Cylinder Bore Fixed to Frame Card Mount Block Secured to Slide Rod Assembly model courtesy: J. Bailey, ANL 9

10. Revised Design Locking Screw with Lock Washer Precision Screws Precision Screw Spring Loaded Positioner Clearance between slide rod and frame Top Kinematic Plate attached to Frame Frame Assembly model courtesy: J. Bailey, ANL 10

11. Beam Finder WireRepeatability Testing 11

12. BFW Repeatability Test Arrangement and Results Physics Requirements: 65 Micron Horizontal & 30 Micron Vertical (RMS) “Keyence” Displacement Sensors (Typ.) Repeatability Test Arrangement 12

13. Production of the BFW 13

14. Vacuum Conditioning 14

15. Beam Finder Wire Status and Schedule 15

16. RFBPM Production Altair End Caps • Production End Caps are in spec electrically and mechanically • Problems with polishing resolved • Production ramping up with 10 sets first received 4/22/08 16

17. Single Piece Transitions Solder Joint Considerations Order of Joining K1 Strongest Design Order of Joining K2 This allows windows to be jointed, tested, and selected before joining to the cavity body. 17

18. Joining Window to Transition • Use of a Moly ring limits the expansion of the copper which then limits the compression of the glass window. 18

19. Brazing Fixture • This is the body mounted in the fixture for joining the Transitions to the Body 19

20. RFBPM Windows QC Results 20

21. Monitoring Windows Quality 21

22. Repair of Soldered Assembly 22

23. BPM Window Statistics • Transition and window soldered with Georo filler material • Sub Assemblies are Vacuum checked before brazed to body • In the last run of windows being brazed to transitions there were 11 of 13 defect free parts made. • Transitions are soldered with Orotin to the bodies 23

24. RFBPM Status and Schedule 24

25. Beam Loss Monitor • Beam Line Detector: • Detailed and Assembly Drawings: • (engineering review and tolerancing). • Detector Head. • Detector BFW Mounting Bracket. • Undulator Motion Tracking Adapter. 25

26. Conclusions • Except for the Beam Loss Monitor all other components are in production • Items that have completed production • Vacuum Chamber • Vacuum Chamber Support • Beam Finder Wire Support • BPM Support • Bellows Module : Final Unit 6/6/08 • Items still in the process of production • BPM cavity - (36% complete) : Final Unit 7/31/08 • Beam Finder Wire - (45% complete) : Final Unit 7/8/08 • Quad Spool - (45% complete) : Final Unit 6/24/08 • Long Break Spool and its support : Final Unit 6/18/08 26