# Presentation: 279037

## Magnet Development Infrastructure

**Director’s Review of the Fermilab High Field Superconducting Magnet Program**

- Fred Nobrega
- January 31, 2006

-  Introduction
-  Present capabilities
-  Future capabilities
-  Conclusions

## Introduction

**Superconducting magnet research and development has traditionally been one of the primary functions of the Fermilab Technical Division.**
**The infrastructure available for magnet development in TD has increased continually from the Tevatron magnet production days to the present. **
**The current infrastructure upgrades, directed toward a new generation of accelerator magnets, build on that rich history.**

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## Industrial Building 3

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## Cable R&D Lab

**Has the capability of :**
**Making LARP cable for quads (TQ’s & LQ’S)**
**Nb****3****Sn cable for high field cos theta & racetrack magnets. **
**NbTi & Copper-only cable for stabilizers and splices in high field magnets.**
**R & D Cable for high field magnets.**

**A cable manufacturing machine, obtained from IHEP, is operated in IB#3.  It has the capability of making 42 strand cable.**

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## Cable Insulation & Coil Winding Stations

**Coil Winding Station.  2 exist in IB3. **

**Cable Insulating Line**

**The cable insulating line and short coil winding stations have been used in IB3 for all short models since the Tevatron.**

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## Reaction Ovens

**Programmable Reaction Oven for Short Coils**

**R&D Reaction Ovens for Strand & Cable**

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## Quadrupole Collaring Press

** ****Quadrupole collaring press in IB3 was used for Tevatron quads and LHC IR Quad 1m models & Nb****3****Sn mech models. **
** ****Will be used to build a collar design Nb****3****Sn short (TQ) & long (LQ) quadrupole.  **

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## Yoke and Skin Press

**Quad Yoke Press for Short Models**

** ****Currently used for HFDA short models**
** ****The press has previously been used for collaring and yoking of SSC Dipole short models.  **

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## Vacuum Oven in IB2

** ****Currently used for SR, HFD and TQ high field magnets.**
** ****Large oven for epoxy impregnation of coils. **
** ****Oven is large enough for 6 meter long magnets. **

**2m O.D. x 8m, t = 60° C, pressure 30 ********m Hg**

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## Coil Curing Oven in IB2

**1.5m x 1m x 7.7m, t = 125° C, pressure is 1 atm**

** ****Currently used for SR, HFD and TQ high field magnets.**
** ****Large oven for curing epoxy of the coils. **
**  ****Oven is large enough for 6 meter long magnets. **

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## Superconducting R&D Lab

**Short Sample Test Facility for SC strand and cable characterization.**

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## Instron

** ****Large & small Instron machines**
** ****Provide wide range of test load capability**
** ****Material testing in tension and compression **

**Instron 8503 & 4411 Materials Testing Machine**

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## Microscopy Lab

*** *****Used for the analysis of Nb****3****Sn strand and cable after reaction **
** ****SEM with a resolution of 3.0 nm*****. ***
*** *****Optical microscope**

**JEOL Scanning Electron Microscope**

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## Industrial Center Building

**ICB is currently being used to build LHC IR Quads.  It includes winding tooling,  curing presses, collaring presses, and a yoke press, all with 6 m long capabilities. Tooling and presses used for cold mass fabrication are scheduled to move to IB3 this year.**

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## Long Coil Winding, ICB

**Long Coil Winding Machine**

** ****Programmable long coil winder produces uniform and repeatable coils.**

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## Long Coil Curing, ICB

** ****Curing press is used to set the coil size for reaction, as well as allow the coils to be easily handled.**

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## Coil Measuring, ICB

** ****Automatic azimuthal coil size measurements**

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## Shell Welding Press, ICB

** ****Long yoke press with automatic linear welding capability**

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## Other Tooling

**In addition to the traditional pieces of equipment, many other types of tooling are available.  Lifting fixtures, roll-over tables, and devices for manipulating coils and magnets will be used.**

**Lifting **
**Devices**

**Rollover Fixture**

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## Design Specific Winding Tooling

**Fermilab has design-specific tooling for several coil sizes:**

_**Available winding mandrels**_**:**
** ****43 mm dia (from HFDA Dipole coils)**
** ****70 mm dia (from LHC IR Quad inner coils)**
** ****90 mm dia (made for LARP quadrupole)**
** ****102 mm dia (from LHC IR Quad outer coils)**

**EDM’d Blocks**

**Strongback**

**Key inserts**

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## Design Specific Curing Tooling

_**Available Curing Molds (short & long)**_**:**
** ****104 mm inside dia (used for HFDA Dipole coils and LHC IR Quad inner coils)**
** ****136 mm inside dia (used for LARP Quad coils and LHC IR Quad outer coils)**

**Shim Blocks**

**Precision laminated mold cavity**

**Electric Heaters**

**EDM’d End Plate**

- More details on how this tooling will be used is in Giorgio’s talk, “Nb3Sn Technology Scale-up”.

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## Future Capabilities

**The objective:**
- is to establish an infrastructure for the scale up of Nb3Sn magnets
**The Results:**
- will enable LARP & core program long magnet fabrication capabilities
- allows for future LHC quadrupole production possibilities

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## IB3 Fabrication Floor Layout

- Instron Lab

- SC Cable Lab

- SEM

- Techs Office

- 6m Oven

- 2m-4m Winder

- Shell Welding Press

- Curing Press

- 6m Winder

- Cable Insulation Line

- Collaring Press

- 1m Winder

- R&D Ovens

- Short Curing Press

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## Long Reaction Oven Procurement

**One of 2 modules for 6m long oven**
**Photo taken at L&L Special Furnace Co. 1/12/06**
**Qualification test at Fermilab ~ 1****st**** week in April, 2006**

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## Backup Generator

** ****100 kW backup generator**
** ****Used for ovens in case of a power failure during coil reaction**

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## Schedule Milestones

**Complete commission of 6m oven, May 2006**
**Start 2m dipole mirror winding, April 2006**
**Start 4m dipole mirror winding, Sep 2006**
**Complete ICB tooling move to IB3, Dec 2006**

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## Conclusions

- Technical Division at Fermilab has a world class magnet R&D infrastructure & will soon have the capabilities to make Nb3Sn coils up to 6m long.
- Large investments in tooling, both generic and design-specific, were made to develop and build superconducting magnets.
- This infrastructure is a key element for the success within LARP and other magnet R&D programs.
- Technical Division has the tooling and personnel required to build and test magnets, as well as do R&D on cable and strands of various materials and configurations.

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