# Presentation: 650501

## LARP Collaboration Meeting TQS01 - Progress

- Shlomo Caspi
**Lawrence Berkeley National Laboratory**
**April 26-28, 2006**

## Outline

- TQS01 - Construction
- Design and Analysis
- Preliminary test results

- S. Caspi

## Statement of work – TQS01

_*One of the main objectives:*_
- Compare the magnet performance with the design parameters.

- S. Caspi

## TQS01 Main Features

- A **2 layers** Nb3Sn Quadrupole
- A 10mm wide 27 strand cable. (0.7mm MJR strand)
- Short sample 4.2K (B,G,I) : **11.2T, 220T/m, 12.3kA**
- Accumulated Lorentz stress : S_theta=-123MPa
- Accumulated axial force (4 quadrants) : F_z=350kN

- S. Caspi

## TQS01

*TQS01*

**No collars**
**Bladders** for coil azimuthal pre-stress
- B ~ 12 T, stress: 150 MPa, total axial force = 350 kN

- The structure and assembly is different from any previous magnet of this kind

- S. Caspi

## TQS01 – Construction

- Coil winding
- Coil reaction
- Instrumentation
- Impregnation
- Coil sub-assembly
- Structure sub-assembly
- Final assembly and pre-stress

- S. Caspi

## Coil winding at FNAL

** ****A double layer**
** ****Bronze island and end spacers**
** ****Layer 1 wound on a mandrel and cured using a binder.**
** ****Layer 2 wound on top of layer 1 and then cured.**

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## Coils Shipped to LBNL

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## Prepare for  Reaction

**Two coils reacted together**

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## Into Reaction Oven

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## Reaction Cycle (Coils 7 and 8)

**72 hr at 210 C**
**48 hr at 400 C**
**48 hr at 640 C**

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## Post-Reaction

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## Coil - Instrumentation

- Strain gauges and voltage tap attached to trace

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## Ready for Impregnation

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## Impregnation

- Coil placed into impregnation chamber

- Controller

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## Impregnated Coils

- Strain gauges placed on layer 1 island
- Voltage traces

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## Coil-pack sub-assembly

- Coil-pack is a sub-assembly of coils pads and fillers

- Coil Pack is assembled, squared and bolted.

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## Structure sub-assembly, shell, yoke and intermediate gap keys

- 20” OD x 18” ID x 40”long, 6061-T6 aluminum shell, precision machined.
- 1018 steel yoke laminations, 2”-thick

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## SHELL & YOKE SUB-ASSEMBLY,cont’d

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## Final assembly

- Mating the coil pack with the shell & yoke sub-assembly.

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## End Support

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## End plates assembly

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## Axial load components

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## Axial Pre-stress

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## Axial Pre-stress, cont’d

-  25 -Ton hydraulic actuator (9500 psi)

- Axial Loading Rig

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## Azimuthal pre-stress (bladder operation)

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## Complete assembly – return end

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## End splices

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## End splices (pizza box)

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## TQS01 lowered into cryostate

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## Outline

- TQS01 – Construction
- _TQS01 – Design and Analysis_
- TQS01 – Peliminary results (cool-down)

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## Integrated analysis and simulations

- CAD (engineering)

- FEM (magnetic)

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## 3D mechanical analysis: Lorentz forces

- ANSYS
*x, y, *and* z *coordinates of each coil element center
- OPERA
- Computation of J x B (N/mm3) at each *x, y, *and* z *coordinate
- ANSYS
- Computation of J x B  Vel (N)
- Final force applied to each coil node

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## TOSCA

**Maximum field:**
**Layer 1 - straight section**
**Layer 2 - end**

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## Structural Analysis - ANSYS

- _Steps:_
- 	Assembly.
- 	Cool-down.
- 	Lorentz forces 10-15 kA
- _Load Cases:_
- Combinations of azimuthal and axial pre-stress
-  Model with and without friction or glued
-  Blocked turns and individual turns

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## ANSYS model – straight section

- Rule 1 - No azimuthal** **separation at the pole

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## ANSYS model – coil ends

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## Structure – Shell - azimuthal

- Shell and yoke mu=0.6, all other surfaces with friction, mu=0.2

**Low assembly pre-stress**

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## Structure – Axial rods

**Low assembly pre-stress**

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## Azimuthal stress in layer 1 (with friction)

- 4.2 K

- 14kA

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## Training Mechanism

- _Straight section_
- Axial tensile strain in the pole island held by friction releases  when the coil pulls away due to insufficient azimuthal pre-stress.
- _End section_
- Sliding and tarring between the coil and the island due to insufficient axial pre-stress.

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## Island axial strain- straight section

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**release of axial strain**

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## Ends and axial Lorentz Force

**Lorentz axial force 351/****413 ****(kN)**

**Applied axial force 800**** ****(kN)**
**(with friction)**

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## 0 friction, limited axial load

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## Island axial displacements- end section

**Island displacement**
**(with friction)**

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## Outline

- TQS01 – Construction
- TQS01 – Design and Analysis
- _TQS01 – Preliminary test results_

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**Strain Measurements**

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## Cool-down

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## Rods – measured cool-down stress

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## Shell – measured cool-down stress

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## Shell – measured cool-down stress

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## Island – measured cool-down stress

**Axial tensile stress**
**Compressive azimuthal stress**

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## Ratcheting During Cool-Down

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## Shell ratcheting during cool-down

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## Coil ratcheting during cool-down

**ratcheting in theta**

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## Coil ratcheting during cool-down

**Minimum /no ratcheting in Z**

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## Excitation

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## TQS01 4.45k Training

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## Layer 1 center island

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## Coil Center Details

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## Coil End Details

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## Island azimuthal strain during excitation

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## Island strain in θ,  magnet center

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## Island strain in Z,  magnet center

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## Island axial strain (center)

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## Island Stress

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## Island Stress over many quenches

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## Island strain in Z,  lead end

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## Island axial strain (end)

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## Island axial strain (end)

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## StructureShell in θ, z

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## Shell azimuthal strain

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## Shell axial strain

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## Shell stress

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## Shell stress

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## StructureRods in z

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## Rods Stress

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## Rods Stress

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## Summary

- The most “engineered” magnet we ever built.
- Analyzed every component from assembly through cool-down and excitation and pushed Nb3Sn technological to new limits.
- The design expectations are:
- Reach short sample prediction (field, current, stress)
- Get there with minimum training

- S. Caspi

## Summary ...

- First quench – Q1 at 80% of ss (176 T/m)
- Plateau  – Q12 at 86% (190 T/m)
- Thermal cycle on TQS01
- Data reduction and analysis:
- Strain gauge measurements
- Quench locations
- Refine ANSYS analysis
- If evidence suggests a problem in coil 6 ramp area:
- Replace coil 6 with spare and retest
- Section ramp area

- S. Caspi