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11T Cable production and QA/QC

This review discusses the cable quantities, production schedule, and quality assurance/quality control (QA/QC) tests for the 11T dipoles at the collimator section for the HL-LHC. It covers cable production, online and offline QC tests, database management, and concludes with an overview of the QA/QC procedures being prepared.

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11T Cable production and QA/QC

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  1. 11T Cable production and QA/QC J. Fleiter, A. Bonasia and A. Ballarino Review of the 11 T Dipoles at Collimator Section for the HL-LHC CERN, 6-8 April 2016

  2. OUTLINE • Cable Quantities and production schedule • Cable QA • QC tests • On line QC tests • Off line QC tests • Database • Conclusion

  3. CABLE QUANTITIES AND SCHEDULE • LS2 • Prototype 4 +1 UL • Series 16 + 4 UL • LS3 • Prototype 4 +3 UL • Series 32 + 6 UL • Cabling machine used also for the production for other HL-LHC magnets (MQXF, MCBX, Q4) • Schedule based on 2 ULs/month throughput (actual production rate) • Plan to increase (x 1.5-2) the throughput of Nb3Sn cables by performing cabling of 3 UL per cabling run instead of one

  4. SPECIFICATION OF 11 T CABLE FOR LS2 • LS2 cables produced from RRP 108/127 strands

  5. QA CABLE OVERALL CERN verifications See B. Bordini presentation Wire manufactured by OST SS 316L core Core approval Wires approval Details in next slide Cabling at CERN CERN, TE-MSC-LMF Insulation performed at CGP (industrial partner, France) Conductor ready for coil winding at CERN

  6. QA OF A CABLING RUN • Three approvals in the 11 T cable production • 1st: 316L core approval • Dimensions • Stoichiometry • 2nd: cabling map approval • Wire selection (class A or class B) • Verification of Production tooling and parameters • 3rd: UL approval • Verification of online QC measurements • Verification of offline QC measurements • Approvals are performed via the superconductor database Wire approval See presentation of B. Bordini 316L core approval Cabling map Selection of tooling and production parameters Cabling map approval Strand re-spooling Cable production Listed in next slide Online QC tests Cable homogeneity Listed in next slide Off line QC tests Cable UL approval

  7. ON LINE QC TESTS: CABLE HOMOGENEITY (1/2) • Cable dimensions: thickness, width and Keystone measured and monitored online with the Cable Measuring Machine (CMM). Same system used as for LHC. • Cabling parameters : monitoring and recording of tension on each individual strand at sampling rate of 50 Hz. New system, installation in May 2016.

  8. ON LINE QC TESTS: CABLE HOMOGENEITY (2/2) • Cable faces Inspection System (CIS): detect crossovers, abnormal flattening of wires or deviation from its nominal shape and inclusions. Same system as for LHC • Cable edges Deformation System: detect abnormal flattening of wires or deviation from its nominal shape, New system, just implemented on production line by A. Gharib and A. Bonasia TE-MSC-SCD.

  9. OFF LINE QC TESTS • Cable Geometry • Dimensions: Ten-stack (point of UL) • Cross section (point and tail of UL) • Sharpness of edges (point and tail of UL) • Facets (1 pitch long samples: point and tail of UL) • Integrity and shape of SS core (point and tail of UL) • Scratch on strands at internal layer (point and tail of UL) • Pitch measurements (point of UL) • Residual twist (point of UL) • Strand Ic measurements (@ 4.2 K and 12 T) • Extracted strand • Virgin strands adjacent to extracted • 3 pairs of strands per UL • RRR measurements • 15 extracted strands per UL • In addition to QC tests, Cable Ictests and local RRR are foreseen

  10. CERN STRAND & CABLE DATABASE • Wire Production and QC Data • Billet parameters • Piece length parameters • Heat Treatment, RT & LT test data from supplier and from CERN • Wire approval for cabling • Cable Production and QC Data • Core approval • Cabling map approval • Piece length parameters • Results from QC tests • UL approval • Wire and Cable Inventory and Usage • Wire, Cable, and Cabling Components (e.g. rollers, mandrels, SS core etc.) • Sorting, Strand Mapping, Cable Map, Summary • QC Samples Barcode generator • Cable Barcode generator See B. Bordini presentation

  11. CERN MAGNET DATA BASE • Barecableregistered in magnetManufacturing and Test Folder (MTF) database by QA team (R. Principe TE-MSC-LMF)

  12. SUMMARY OF 11 T CABLE QA/QC • QA/QC plan built on LHC QA/QC taking into account Nb3Sn specificities • New online QC tests implemented to check homogeneity of cable (edge deformation and strand tension monitoring) • Cable acceptance based on unambiguous criteria: • On line QC tests: verification of cable homogeneity • Off line QC tests from extracted samples • Cables and QC tests results registered in superconductor database • Approved cables registered in the MTF data base • QC procedures being prepared and finalized

  13. Thankyou

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