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FRESCA2 description

This meeting discusses magnet design, coil fabrication, assembly, and test results in the context of EuCARD and EuCARD2 projects, focusing on parameters such as superconducting wire, coil mechanics, operational current, and inter-coil shims. The session covers coil fabrication steps, magnet loading, assembly processes, and issues encountered during the project.

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FRESCA2 description

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  1. FRESCA2 description P. Ferracin, N. Bourcey, M. Durante, P. Manil, G. Maury, J. C. Perez, J. M. Rifflet, G. de Rijk, F. Rondeaux, D. Martins Araujo, E. Rochepault, R. Gauthier, S. SequeiraTavares, G. Willering Meeting on EuCARD and EuCARD2 inserts test preparation in Fresca2 CERN 02 October, 2018

  2. Outline Paolo Ferracin Magnet design and parameters Coil fabrication Magnet assembly Test results

  3. Magnet design and parametersSuperconducting wire and cable PIT strand RRP strand Paolo Ferracin • RRP (132/169) and PIT (192) • Strand diameter: 1 mm • Cu/Sc: 1.3  56% Cu • Strand #: 40 • Bare width after cabling • 20.90 mm • Bare thickness after cabling: • 1.82 mm • Braided insulation: 0.16 mm

  4. Magnet design and parameters Coil design Paolo Ferracin • Two double-layers • 36 and 42 turns • Bore aperture 100 mm • Iron and Ti poles • 730 mm of straight section • 1% homogeneity over 540 mm and 2/3 of aperture • Hard-way bend of 700 mm minimum radius • 17 inclined ends • Overall coil length of 1.6 m • Magnetic length 1.2 m

  5. Magnet design and parameters Support structure • OD: 1.030 m; length: 2.255 m • Al shell, 65 mm thick, 1.6 m long • Bladder and key pre-load • Similar to LBNL HD2 concept • Iron yoke • Holes for axial rods • Bladder slots • Horizontal stainless steel pad • 3 bladders, 75 mm wide • 2 load keys • Vertical iron “boat” • 2 bladders, 60 mm wide • 2 load keys • Al rods and end-plate for axial support Paolo Ferracin

  6. Magnet design and parameters Operational current and margins Paolo Ferracin • Operational condition (13 T) • Iop: 10.82 kA • Bpeak_op: 13.34 T • 78%of Iss at 4.3 K • 72%of Iss at 1.9 K • 15 T bore field (“ultimate”) • 85% of 1.9 K Iss • Peak field in layer 1 • 10% of margin in the ends • At Iop, total stored energy • 3.6 MJ

  7. Magnet design and parameters Mechanics Paolo Ferracin • LHC MB vs. FRESCA2 • Fx: 340 t/m 1500t/m • Fz: 27 t 300 t • 13 (15) T pre-load  coil stress <150 (200) MPa

  8. Outline Paolo Ferracin Magnet design and parameters Coil fabrication Magnet assembly Test results

  9. Coil fabrication steps Paolo Ferracin Winding (CEA), reaction (CERN), instrumentation/splicing/impregnation (CERN)

  10. 4 coils fabricated and instrumented(2 spares to be completed in February 17) Paolo Ferracin

  11. Outline Paolo Ferracin Magnet design and parameters Coil fabrication Magnet assembly Test results

  12. Magnet assemblyInter-coil tailored shim Paolo Ferracin

  13. Magnet assembly1st pole Paolo Ferracin

  14. Magnet assemblyCoil pack Paolo Ferracin

  15. Magnet assemblyHorizontal pads Paolo Ferracin

  16. Magnet assemblyYoke and shell Paolo Ferracin

  17. Magnet assemblyYoke and shell Paolo Ferracin

  18. Magnet assemblyCoil pack inside the structure Paolo Ferracin

  19. Magnet loading Transverse loading bladders & keys Longitudinal loading piston & rods Paolo Ferracin

  20. Magnet loading zrod xcoil shell Paolo Ferracin

  21. Magnet assemblyConnection box Paolo Ferracin

  22. Magnet assemblyConnection box Paolo Ferracin

  23. Magnet assembly Paolo Ferracin

  24. Magnet assembly Paolo Ferracin

  25. Magnet assembly Paolo Ferracin The overall diameter is on the left part is 99.85 mm and the right part is only 99.32 mm. The calculation of the max inscribed cylinder gives a diameter of 99.48 mm. When calculating the max inscribed cylinder along the bore with the two end-plates the max diameter is 99.21 mm

  26. After loading • Ux: -0.070 mm • Uy: +0.004 mm Paolo Ferracin

  27. After cool-down • Ux: -0.300 mm • Uy: -0.190 mm Paolo Ferracin

  28. 13 t • Ux: +0.010 • Uy: -0.300 mm Paolo Ferracin

  29. Magnet assemblyFRESCA vs FRESCA2 Paolo Ferracin

  30. Outline Paolo Ferracin Magnet design and parameters Coil fabrication Magnet assembly Test results

  31. Outline Paolo Ferracin Introduction Magnet design and parameters Coil fabrication Magnet assembly Status

  32. Test results Paolo Ferracin Record fields: 14.6 T at 1.9 K, 13.9 T at 4.5 K Stable fields: 14.4 T at 1.9 K, 13.6 T at 4.5 K

  33. Appendix Paolo Ferracin

  34. Magnet design and parametersQuench protection • Traces with 4 heaters • Wiggling shape for better coverage with 12 mm width • 9 voltage taps per layer • Monitor pole turn and external turns Paolo Ferracin • Stored energy density of 150 MJ/m3 • Comparable to other Nb3Sn dipoles and quadrupoles • Protection system: dump resistor and quench heaters on all layers • 50% coverage • 150 or 200 K of peak T with tdetection of 40 or 100 ms

  35. Cable volumetric change during heat treatment • Cable dimensional variation during HT included in tooling design • About +3% in width • About +4% in thickness • About -0.1 to -0.3% in length • Tests with simplified tool • Modification of reaction tooling for axial contraction • 2 gaps closed after winding Paolo Ferracin

  36. Issues during coil fabrication Paolo Ferracin • Pole deformed after reaction • Re-machined after impregn. • Broken strands during splicing • Added Cu stabilizer in damaged area • Incomplete impregnation of 2 coils • New injection holes and better control of polimerization

  37. Fresca2Effect of load, cooling down and nominal field on the aperture Douglas Martins Araujo & Paolo Ferracin MSC-MDT 27/9/18 - D. Martins Araujo

  38. Aluminium Shell Specification Vpad Yoke Hpad Iron pole Titanium pole 27/9/18 - D. Martins Araujo

  39. Bonded contacts coils - poles Lorentz forces Sliding contacts coils - poles With Reluctance forces Titanium pole - Usum - Room T. 27/9/18 - D. Martins Araujo

  40. Bonded contacts coils - poles Lorentz forces Sliding contacts coils - poles With Reluctance forces Titanium pole - Ux - Room T. 27/9/18 - D. Martins Araujo

  41. Bonded contacts coils - poles Lorentz forces Sliding contacts coils - poles With Reluctance forces Titanium pole - Uy - Room T. 27/9/18 - D. Martins Araujo

  42. Bonded contacts coils - poles Lorentz forces Sliding contacts coils - poles With Reluctance forces Titanium pole - Usum - Cool-down 27/9/18 - D. Martins Araujo

  43. Bonded contacts coils - poles Lorentz forces Sliding contacts coils - poles With Reluctance forces Titanium pole - Ux - Cool-down 27/9/18 - D. Martins Araujo

  44. Bonded contacts coils - poles Lorentz forces Sliding contacts coils - poles With Reluctance forces Titanium pole - Uy - Cool-down 27/9/18 - D. Martins Araujo

  45. Bonded contacts coils - poles Lorentz forces Sliding contacts coils - poles With Reluctance forces Titanium pole - Usum - Nominal Field 27/9/18 - D. Martins Araujo

  46. Bonded contacts coils - poles Lorentz forces Sliding contacts coils - poles With Reluctance forces Titanium pole - Ux - Nominal Field 27/9/18 - D. Martins Araujo

  47. Bonded contacts coils - poles Lorentz forces Sliding contacts coils - poles With Reluctance forces Titanium pole - Uy - Nominal Field 27/9/18 - D. Martins Araujo

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