Fermilab SRF Program and FNAL

1. Fermilab SRF Program and FNAL/ANL SRF Infrastructure Shekhar Mishra Fermilab

2. Outline Infrastructure for Cavity and Cryomodule Fabrication, Processing and Testing Present US Infrastructure Components of the SRF facility Cavity Fabrication through Industry Cavity Processing Vertical Test Facility Horizontal Test Facility Cryomodule Assembly Facility Cryomodule Testing Facility (with and Without beam) Summary

3. Present: US SRF Infrastructure Limited cavity fabrication capability in US industry One US company (AES) fabricating SRF cavity Developing three new companies (Niowave, Roark and PAVAC) Cavity Processing and Vertical Testing R&D Facility Jlab (~30 FY07, ~40 FY08, ~40 FY09) cycles/yr ANL/FNAL ( ~40 FY09 and beyond) cycles/yr Cornell ~12 cycles/yr VTS @FNAL ~50 cycles/yr (FY09) Significant fraction of this capacity is used to support R&D Program Process development Single cell Processing Horizontal Test Stand FNAL ~24 cavities/yr Cavity Dressing and Cryomodule Assembly FNAL 2-4/yr (FY07) (These facilities are very important for our R&D. These have a single line of processing and no Redundancy in the system.)(These facilities are very important for our R&D. These have a single line of processing and no Redundancy in the system.)

4. Cavity and Cryomodule

5. Scope: US Laboratories Capacity

6. Fermilab SRF Infrastructure Cavity Fabrication Increased cavity fabrication R&D and training US industry 2nd Eddy Current Scanner Optical Inspection Device Automated Cavity Tuning 100+ Cavity/yr ( by FY09) Cavity Processing Facility (Pre-Production Facility, existing technology with industry, modular and redundancy) 200+ Cycles/yr (by FY12) Vertical Testing Additional 125+ Cavity/yr (by FY12) Horizontal Test Stand Additional 48 Test/yr (Maximum US Capacity needed) Cryomodule Assembly 1 per month Material R&D

7. Cavity Processing Facility The term �process� defines the complete procedure that transforms a fabricated cavity into a fully qualified cavity at a specified operating gradient and quality factor (for ILC: 35MV/m and 0.5-1.0e10). It includes the following operations: Cavity processing Cavity tuning Vertical testing Cavity Processing Facility (CPF) Receive, QC and store fabricated cavities Perform internal and external chemical processing Perform high pressure rinsing Perform high and low temperature cavity bakes Tune cavities for fundamental frequency and field flatness Prepare cavity for vertical test Receive vertically tested cavities Install helium vessels (dress cavities) Prepare dressed cavities for horizontal testing Receive cavities from HTS and send to string assembly facility (CAF)

8. Cavity Processing Facility At ANL/Fermilab A New Cavity Surface Processing Facility to Support: ILC S0/S1 goals Fermilab�s proposed Project X (~40 Beta=1.0 cryomodules in 3 years) Requirements: Initial capability: 100 processes per year (~30 cavities) Building size sufficient for eventual upgrade to 400 processes/yr. Multiple lines of processing equipment, including clean rooms 12-20,000 square foot building required Schedule: FY09: Identify existing FNAL/ANL building and refurbish; facility design FY10: Begin Construction Procure long lead time items: EP and BCP cabinets, clean rooms Build/install: HPR, UPW and scrubber systems FY11: Complete installation and commission facility FY12: Begin upgrades for 400 processes/yr.

9. Proposed CPF Layout

11. ANL/FNAL cavity processing facility New High-pressure rinse system

12. Alternative: An Off-Site CPF A contract could be written for the design, construction, and operation of an off-site facility located very near FNAL. Facility would be financed by DOE funds and owned by government, but operated by industry Advantages: Operation by an experienced electro-polishing industrial firm using their manpower Significantly reduces the need for large quantities of nasty chemicals on FNAL site Others? Fermilab/ANL has started some initial work with ABLE Electro-polishing company in Chicago.

13. Off-Site CPF Scope of Work

14. FNAL Vertical Cavity Test Facility Design Existing 125W@ 2K Cryogenic plant; 1.5K minimum RF system in collaboration with JLab 250 W available at cavity Radiation and magnetic shielding < 5 mrem in an hour immediately outside the shielding <0.25 mrem/hr in normal working areas <10 mG Thermometry for quench location Capable of testing ~50 Cavities/yr Status One Vertical Test Stand (VTS1) commissioned 7/2007 17 cavity test cycles in FY08 (ILC 1- & 9-cell, SSR1) Evolutionary upgrades 9-cell Thermometry 2 cavities at a time Cryogenic system & infrastructure upgrades Plan for two additional VTS cryostats Ultimate capacity ~ 250 cavity tests/yr

17. VCTF Upgrade Scope

18. Horizontal Test Stand - 1 Horizontal Test Stand was fabricated in FY07-08 Vacuum vessel (mini-cryomodule) 1.8 K cryogenic plant/distribution Clean vacuum systems for cavity/coupler High-power (at least ~300 kW) pulsed RF (klystron/modulator), LLRF control system Cavity diagnostics X-ray detectors Dark current detectors (Faraday cups) Thermometry DAQ and controls system Horizontal Test Stand - 1 is operational with 3.9 GHz cavity at MDB The maximum capacity of this test stand is ~24 cavities/yr In the Spring of 09 it will start testing 1.3 GHz cavity. The commissioning of the HTS will happen with AES cavity followed by high gradient cavities. Cavity processed and tested at Jlab/Cornel/ANL/FNAL Tuner from INFN, Coupler from SLAC Cavity Dressing at Fermilab

20. Proposed: Horizontal Test Stand - 2 We proposed to build a second Horizontal Test Stand at Fermilab and install it next to HTS-1. to supplement and increase throughput of current HTS Main difference: cryostat will house 2 cavities Cool and power 2 ILC/PX cavities at once Test bench for driving multiple cavities from 1 klystron Ability to test two cavities as a string Cool and power cavity + BPM or magnet Allow for flexibility in cavity/coupler designs

21. HTS1 and 2 in MDB

22. Cavity Dressing and Cryomodule Assembly Facility CAF is an upgraded version of the infrastructure in DESY Hall 3 for cryomodule assembly: Cavity String Assembly Cold Mass Assembly Vacuum Vessel Assembly Final Assembly Cryomodule Assembly Facility (CAF) at Fermilab consists of 2 buildings: CAF-MP9 and CAF-ICB. The ultimate throughput of this infrastructure will be to assemble 1 cryomodule per month.

23. CAF-MP9 CAF-MP9 houses the string assembly clean rooms, the rail for string assembly under the clean room extending to the cold mass assembly area and the cold mass assembly fixture adjacent to the clean room.

24. CAF-ICB CAF-ICB houses the Vacuum Vessel Assembly area and Final Assembly area including the Big Bertha Fixture.

25. CAF-MP9

26. CAF-MP9 Infrastructure Cavity String Assembly Clean Room A large (~250 square-meter) clean room was specified and procured in FY05 and installed in FY06 at Fermilab. The cavity string assembly clean rooms infrastructure consists of: Class 1000 ante clean room area: Preparation of the dressed cavities for transportation into the assembly clean room. Class 100 area Parts and Fixtures preparation for assembly Class 10 assembly clean room area: Where the cavities vacuum is vented to interconnect them with bellows.

27. CAF-MP9 Infrastructure (cont.) Other infrastructure: String Assembly Fixtures Vacuum / Ultra Pure Gas Flow Equipment/ Hardware Ultrasonic Cleaner Ultra pure DI water Cavity Handling Cart / Fixtures Cold Mass Assembly Fixture

28. CAF-ICB

29. Cryomodule Transport � Module weight: ~8000kg, Girder Weight: ~2250 kg, 5 cross members: ~1000 kg each � Fixture to transport completed Cryomodule from CAF-ICB to the ILCTA-NML � Ten helical cable isolators (or shock absorbers) were used to protect the cavities from extreme acceleration � Max. expected shock load during the transport of CM1 to NML is less than 0.25 g

31. Cryomodule and RF Unit Test ILCTA_NML will test 2 Cryomodule with beam in the present building configuration. Hooks will be in place for ILC beam test later if desired. Status DESY Cryomodule CM1 is ready. We are preparing the safety and other necessary document to start cool down at ILCTA_NML at Fermilab. A 10 MW Klystron is under test at SLAC. (US-Japan Collaboration) Modulator (Fermiab) and RF distributions (SLAC) are under fabrication and test. Proposed Plan Cool down the Capture cavity 2 and CM1 in CY09. RF power FY09 using the 5 MW Klystron High Gradient CM2 should be deliver to ILCTA_NML by end of CY09

32. New Phase-1 Layout of ILCTA_NML

33. CM1 getting Ready for Test

34. Current Picture of NML

35. Cryomodule Test Stand Fermilab plans to build a Cryomodule test stand to test all the elliptical cavity cryomodule. Cryomodule Test Stand will be used to Test all cryomodule assemblies Mechanical checks Alignment of tubes, flanges, etc. Leak checks of all volumes Conditioning of main RF-couplers Cryo load measurement, Q and Eacc SC magnet power test Dark current measurements

36. XFEL Module R&D Test Stand

37. DESY CMTB -- view from end

38. Summary The Main Linac Cavity and Cryomodule R&D program and Infrastructure development would Contribute toward the critical SRF R&D Build a minimal facility needed for Project-X at Fermilab Train people in SRF at Fermilab Get the US industry involved from the initial phases for the possible participation in ILC.