Material for Large Scale Cavity Production

1. Material for Large Scale Cavity Production W. Singer, X. Singer, DESY B. Spaniol, W.C. Heraeus PresentedbyWaldemar Singer

2. Material main issues • First experiences with cavity material for XFEL • - Qualification of Nbsuppliers for XFEL • - Current status of the material contract for XFEL cavity • Where is the bottle neck for large scale material production? • Remarks

3. Qualification of Nb suppliers for XFEL • 5 qualified companies About 15-20 t. of high purity niobium are required • Three qualified for FLASH Nbsuppliers: Wah Chang (USA), Tokyo Denkai (Japan), HERAEUS (Germany). • Several companies anticipated to be qualified for XFEL (CBMM, GIREDMET, Plansee, OTIC Ningxia) • Three steps of qualification for XFEL have been determined: • Step 1. Material testing (RRR, Microstructure, Eddy current scanning, Tensile test, Hardness, Impurity content). • Step 2. Single cell cavity fabrication at DESY, treatment and RF tests at DESY. • Step.3. Nine cell cavity fabrication at Industry, treatment at DESY and RF tests. • Only two companies Plansee(Austria) and Ningxia OTIC (China) successfully passed all three steps. 5 companies qualified for XFEL currently

4. Status: Material for XFEL Cavities Material for 680 Cavities will beprovidedby DESY to RI and E.ZANON Mid 2011 – Beginning 2013 • Contracted January 31st, 2011 to companies: • W.C. Heraeus, • Tokyo Denkai, • OTIC Ningxia, • SE Plansee >15 000 piecesofsemifinishedproducts (sheets, tubes, etc.)

5. Current status of contract:Material procurement • DESY has taken over the responsibility for • incoming QC • testing for required parameter (RRR, HV etc.) • scanning of sheets • documentation (guarantee of traceability for pressure bearing parts) • definition of numbering system and marking • delivery to company One of the aspects of the QC is the eddy current scanning. New equipment for eddy current scanning of XFEL niobium at DESY

6. Independent from company QC and acceptance on company site are indispensable • In House (DESY) • RRR • Scanning - Apparatus • Interstitial impurity analysis (H,N,O, C) • Metallic impurities analysis (another RM, Fe, Ni etc.) • Metallography • Tensile test • Hardness, HV • Surface roughness • Thermal conductivity • Outsource • NAA Neutron Activation Analysis • Radiation Fluorescence Analysis • SEM, EDX • SIMS, XPS, AUGER • X-ray radiography • Neutron radiography • Texture analysis • Bulging test Scheme of QC of Nbsheets

7. Material PED (Pressure Equipment Directive) Activities • The notified body (TUEV NORD) will supervise the material procurement PED Activities • Qualification of cavity material Nb40, Nb300, NbTi, Ti1 and Ti2 (creation the particular material appraisal (PMA)). • W.C.Heraeus and SE Plansee have a current PED certification • Certification of QM system at the companies Tokyo Denkai and Ningxia OTIC by TUEV NORD. Audit of TUEV is foreseen for March 2011 • Supervising of the semi finished material products procurement (traceability, marking, 3.1 test certificates etc.)

8. Remarkstoprocurementof material for XFEL cavities 1. DESY will purchase the material and ship to RI and E. Zanon This is reasonable from the commercial point of view, but less reasonable from the technical point of view. Semi finished products can be more optimally adopted to requirements of the cavity producers, if the cavity producers would order the material themselves 2. Without qualification of new suppliers (Ningxia OTIC, Plansee) we would not have enough material for XFEL cavities (ca. 15 t in 2 years).

9. Where is the bottle neck for large scale material production? H.Umezawa (Tokyo Denkai) Three bottle necks Nb raw material with low content of Ta (facilities for liquid - liquid extraction, Nb ore with low Ta content) Melting capacities Nb sheet production process

10. TESLA Industrial Study 2002 TESLA Industrial Study: „Productionof Niobium withtheQuality RRR300“ K.-H. Wahl, B. Spaniol. 19.11.2002 Main costs: raw material (21%), EB melting (49%), sheetrolling (17%)

11. Comparison of the TESLA Study and the actual situation is showing strong deviations: • - Costs of row material increased currently by factor 3 • The melting costs in the Tesla Study are high (investment in new EB furnaces) • - The rolling costs in the study seems to be too low

12. Possible Solution TESLA Study proposal as a safety solution was to build 5 new EB facilities. In 5 years the material for 20.000 TESLA cavities can be melted Each Nb producer has a main business (core business). The main business is not our high purity Nb (Tokyo Denkai - Ta, Heraeus - Nb1%Zr, Wah Chang - NbTi etc.) Otherwise the availability of Nb for ILC will depend on current situation on the market and presence of another big projects (like ITER now) Or the time of delivery has to be significantly increased

13. Alternatives: Large Grain LG Cavity • LG ingot and disc fabrication Cutting of the large grain Ingots by wire sawing at W.C.Heraeus • Development of LG disc production was done within the framework of the XFEL R&D program of DESY and the W. C. HERAEUS.

14. Alternatives: Large Grain LG Cavity • XFEL Requirement 11nine-cell DESY cavities from LG Nb of Fa. HERAEUS are fabricated at Fa. RI Treatment: 100µm BCP, 800°C 2h, 20µm BCP, HPR and 125°C, 50 h baking. 100 µm BCP done at Fa. RI.

15. Alternatives: Large Grain LG Cavity • LG ingot and disc fabrication Tokyo Denkai

16. 9 - cellhydroformedcavities Z145 Z163 Z164 9-cell cavity from hydroformed at DESY units completed at JLAB

17. Thank you