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Undulator Vacuum System

Undulator Vacuum System. Dean R. Walters Soon-Hong Lee, James Bailey, James Morgan, Dana Capatina , Scott Doran, ANL Lou Ann Tung, LLNL. Undulator Vacuum System. Beam Finder Wire Chamber Vacuum System. BFW In Situ- Short Break. BFW. Undulator. Undulator. Beam. Girder. Girder.

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Undulator Vacuum System

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  1. Undulator Vacuum System Dean R. Walters Soon-Hong Lee, James Bailey, James Morgan, Dana Capatina, Scott Doran, ANL Lou Ann Tung, LLNL

  2. Undulator Vacuum System • Beam Finder Wire • Chamber • Vacuum System

  3. BFW In Situ- Short Break BFW Undulator Undulator Beam Girder Girder

  4. 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 Vacuum Pump Connector (2.75” Conflat Flange) Vacuum Chamber Connection Flange (NW-50 CeFix w/Clamp) Adjustable Mounting Support Beam Port

  5. BFW Prototype Setup “Keyence” Sensors Supports Read Out Precision Screws Kinematic Stop Plates Engaged Vacuum Line Fixed Frame Movable Assembly Air Supply Line 70 psi Pneumatic Cylinder Vacuum Chamber Bellows

  6. BFW Prototype Results • Vertical Repeatability: +/-7 Microns • Horizontal Repeatability: +/- 14 Microns (Extrapolated to account for lever arm) • Adjustability: +/- 2 Microns • Required Force on Kinematic Stop: 20 lbs. • Slide Rod Clearance: 0.020” • Top Locking Screws: Lock Washers OK

  7. Assemblies and Cross Sections Assembly Bellows Flange BFW Flange Seal Locating Pins Beam Tube Spider Shielding Cut-out Vacuum Flange Vacuum Chamber Flange

  8. BFW Production Schedule

  9. Beam Finder Wire Final Design Review Report A final design review of the APS/LCLS Beam Finder Wire (BFW) was held on September 20, 2006 at Argonne National Laboratory. Recommendations: The ANL/SLAC team should proceed with the fabrication of the Beam Finder Wire Assembly and the BFW Support Assembly excluding the Wire Card Assembly. The Wire Card Assembly should have a design review after final material selections are complete.

  10. X-Adjustor Z-Adjustor Support Assembly Production Vacuum Chamber Ass’y Vacuum Chamber Assembly

  11. Measurement results of magnetic permeability (r) • Anneal conditions • Vacuum pressure at 1.0 x 10-4 Torr • 1,750 º F for 30 minute soaking on 20Cb-3 and 1,950 º F for 30 minute soaking on the other types • Rapid Nitrogen gas quenching • 316LN had stable permeability values of less than 1.010, even if cold-works and welding. • 310S and Nitronic 40 had increased in permeability after welding significantly. • 20Cb-3 had acceptable permeability values less than 1.020 (most less than 1.010) and good welding characteristics (less heat-affected zone) • Nitronic 33 and 20Cb-3 had increased in permeability after annealing.

  12. B/B < 1.5 x10-4 8.0 mm Hall probe holder Measurementsof the changes of applied magnetic fields • Sample chambers under APS undulator "A" • A 3-inch-long sample vacuum chamber was inserted Into a hybrid permanent magnet undulator with a 3.3 cm period and 8 mm min. gap • To Investigate high magnetic field influence to the relative magnetic permeability • Peak of applied magnetic field: ~ 1.2 T Undulator A Sample chamber

  13. Fabrication Processes SST Sheets (144” x .75” x .120”) 316LN SST SST Plate, End Cap (144” x 7.5” x 1”)(144” x .5” x.25”) 20Cb-3 Polishing/Milling Milling/Polishing Seam Welding Final Machining Cleaning/Baking Coating

  14. NW 50 Flange -Clamp Type (316L SST) Compound screws (Brass Screws & SST ) Vacuum Chamber Chamber Strong-back (316 SST) Chamber Strong-back (20Cb-3) Top & Bottom Strips (20Cb-3) Top & Bottom Strips (316LN) End Cap (20Cb-3) End Cap (20Cb-3) Prototype Vacuum Chambers Prototype A Prototype B

  15. SUT Machining Results • Material: Austenite stainless steel 316 • Supplier: Walco Tool & Engineering • Parallelism of chamber surfaces (0.100 mm): 0.250 mm • Thickness of chamber (6.00 ~ 6.08 mm) : max. 6.15 mm • Straightness of chamber edge (± 0.200 mm) : max. 0.406mm bowed • Vibratory or thermal stress relief is required, which may restore the original properties of the base metal E H

  16. Prototype B Machining Results • Material: Austenite stainless steel 316 • Supplier: Dial Machine Inc. (measured Aug. 8, 06) • No attempt was made to tweak in, or adjust, the constrained condition to improve the results. • Flatness of nose bottom surface in the clamped condition (0.100mm): 0.314mm • Parallelism of nose bottom surface to strongback bottom in the clamped condition (0.100mm): 0.198 mm • Parallelism of nose top surface to nose bottom surface in the clamped condition (0.100mm): 0.107 mm • Straightness of chamber edge (180.0± 0.20mm) : 179.54~179.70mm (0.160mm bowed) • Thickness of chamber every 12” in the clamped condition (5.0±.08mm) : 4.945~5.112mm • Flatness of the surface of machining fixture in the strongback clamped condition: 0.04mm • Flatness of the bottom surface of strongback in the free state: 1.143mm

  17. Polishing of Stainless Steel • Samples of True #8 stainless steel sheets from Pacific Plus Inc. of Dallas, TX / Hwa Yang Stainless Steel Group in China. • True #8 and super #8 are trademarks of Pacific Plus International, Inc. • 1.5 mm thick 316 SST sheets (1 ft x ft) and 0.5 mm thick 304 SST sheet (4 ft x 8 ft) were bought to evaluate the impact of manufacturing operation on the surface finish. • Samples were polished at Fine Art Inc. and Polished Metals Limited. • Measurements • Used Tencor Alpha-Step to obtain a 2D surface profile. • Used MicroXAM RTS surface profiler (White light interferometry) MicroXAM RTS from www.ade.com

  18. WLI Sample: #PLM 2 Mode: PM Objective: 50x Size: 0.244 x 0.244 mm2 r(z): -1867 mm; hrms: 27.9 nm # 8 x’rms: 14.4 mrad; z’rms: 3.6 mrad Sampled Data (1024x1024) Lineout (x: #200; z: #300-#400) Full Spectrum (1024x1024) Sample: #PLM 2 Size: 0.130 x 0.130 mm2 AFM r(z): -907 mm; hrms: 13.5 nm x’rms: 24.4 mrad; z’rms: 8.2 mrad Sampled Data (500x500) Lineout (x: #200; z: #300-#400) Full Spectrum (500x500) Evaluation of Roughness Scans - Polished For wakefield considerations, the beam- (or z-) direction is the most important and all measurement results are within tolerance, i.e., have rms derivatives in z of less than 10 mrad.

  19. CO2 Laser Weld PrototypingInspection Results for Sample 3 Intermittent weld Seal weld Groove

  20. Laser Welding/Final Machining Prototyping 42” Prototype After Laser Welding and Before Final Machining

  21. CO2 Laser Weld Prototyping42” Vacuum Chamber Prototype Fixturing for end cap welding Fixturing for strong back welding Welding strong back Welding end cap

  22. Final Machining Prototyping Machined to red line both sides Vacuum Chamber Gap Actual Weldment Six Inch Long Prototypes

  23. Final Machining Prototyping T/C Measurement 1” Dia. End Mill Dial Indicator Machining of 6” Long Prototypes

  24. Final Machining Prototyping Preliminary Inspection Results for the 42” Prototype • <0.002” Flatness & <0.002” Tolerance on Thickness

  25. Coating Basics

  26. Pictures of test set up operating • Coating in a 35 mm SST Tube

  27. Test set up operating Coating inside a 7.9 mm Glass tube Coating inside a 12.7 mm Glass tube

  28. Samples Measurements of samples Measure thickness of 560 nm, 240 nm, & 130 nm Deposition Rate of 23 nm per minute

  29. May Apr. May June July Aug. Sept. Oct. Nov. Dec. Jan. Feb. 2006 2007 Mach/ Coat Mach/ Coat Fab. Fix. & Weld Fab. Fix. & Weld Prototype Development Prototype A Strongbk. Strongbk. Strongbk. Strongbk. Strongbk. P.O. 20Cb-3 Mach. End Cap End Cap End Cap End Cap End Cap Proc. 20Cb-3 & Initial Mach. Side Walls Side Walls Side Walls Side Walls Side Walls Polish Sheet Intl. Mach. Weldment Weldment Weldment Weldment Weldment Prototype B Strongbk. P.O. Proc. 316 L & Initial Mach. End Cap Proc. 20Cb-3 & Initial Mach. Intl. Mach. Side Walls Polish Sheet Weldment

  30. Prototype Development May Apr. May June July Aug. Sept. Oct. Nov. Dec. Jan. Feb. 2006 2007 42” Prototype Parts Proc. 304 SS & Mach. Fixtures (Weld) Design & Fab. Assembly Weld Mach Coat Laser Weld Development 6” Samples YAG @ ANL 18” Samples CO2 @ Vendors Final Mach. Development 6” Samples Mach. @ ANL Design & Fab. Fixtures (Mach)

  31. Prototype Development May Apr. May June July Aug. Sept. Oct. Nov. Dec. Jan. Feb. 2006 2007 Coating Development Part #2 Consultant Agreement Place PO 1St Equipment Design Procure Assy Full Size Setup Power Supply Loan Agr Ship Install Process Dev Bench Test 42” Prt

  32. Chamber Schedule

  33. Chamber Design Review The LCLS undulator vacuum chamber and system were reviewed by a committee composed of John Grimmer, APS, Nadine Kurita, SLAC, Allan Rowe, FNAL, and John Noonan, ANL, chair on September 27 and 28, 2006 Schedule The schedule for fabrication and delivery of vacuum chambers for the undulator vacuum system is tight, especially for the undulator vacuum chamber. This is a complex part with stringent physics requirements, especially the surface finish. Aspects of the chamber are demonstrated, but a full-size prototype will not be complete until December, 2006. The Undulator Vacuum Chamber There are no technical barriers to fabrication of the chambers. However, there are tooling and detailed fabrication issues that need to be answered in order for production to proceed. Successful chamber fabrication will be a significant accomplishment. The physics are stringent Fabrication of the full size prototype chamber is essential and the engineers should have all the APS and LCLS support that they need to complete the fabrication. The full size prototype will determine vacuum integrity, outgassing rates for the chamber, coating surface finish, and dimensional straightness. It is important to perform a test in which the full size chamber is installed in an undulator and its straightness measured. The survey groups need to be involved in the tests and certify that the installation procedure is reasonable. Magnetic measurements need to be repeated on the 20Cb-3 steel. The 20Cb-3 material has no apparent pedigree in demanding vacuum and magnetic applications. The prototype has not yet been welded leak tight and will clearly be "worse" than 316LN in magnetic performance, although the effect of the difference is debatable.

  34. Vacuum System Calculations • In past hand vacuum calculations have been used to estimate the vacuum system performance • Recently a collaboration with LLNL has been established to provide calculations. • Below are the results obtained at this point. • The next analysis will include: -Add in the turbo and roughing pumps (with S(p)) in the long break and an ion pump in all three breaks -Put in the time-dependent outgassing rate for stainless steel (already have fit) -Put in the different rates for copper and aluminum

  35. Long break layout (Short break is the same but without the valve spool)

  36. Pressure profile with one ion pump on the long break with one undulator section Dz = 1 cm All surfaces outgas at 1.6 x 10-11 T-l/s/cm2 cm One undulator section Long break

  37. Conclusions • BFW • Design, testing, and review have been completed. • Committee has agreed that it is ready to enter production • Chambers • This has not progressed as expected. The Strongback delay has rippled through the prototype schedule and it impacts the production schedule. • The Design Review Committee has agreed that the Strongback can enter production, but testing is needed on the full sized prototypes to continue with the production of the whole weldment. • These Prototypes must be done before the end of January so that the production units are not impacted.

  38. CO2 Laser Weld Prototyping42” Vacuum Chamber Prototype Results in Constraint Condition 0.001” 0.002” -0.001” 0.000” 0.001” 0.000” 0.001” 0.000” 0.001” 0.000” 0.002” 0.000” 0.000” 0.000” 0.001” 0.001” Flatness Variation Along Center of Wall Sheet Across Sheet Flatness <0.001”

  39. Vacuum Chamber alignment Vertical Adjustment Screws (14)

  40. On Going Work • Test Set up • Cathode Guides • Straightening of Cathodes • Tensioning of Cathodes • Vertical positioning • 42” chamber • Full size setup • Vertical Coating Stand

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