# Presentation: 844796

## LQS report

- Paolo Ferracin

- LARP Collaboration Meeting
- FNAL
- October 27, 2008

## Outline

- Task goals
- Magnet design and assembly procedure
- Magnetic and mechanical analysis
- Assembly, loading, and cool-down of a 850 mm long segment with dummy coils
- Assembly of full-length shell-yoke sub-assembly
- Conclusions and next steps

- 10/27/2008

- Paolo Ferracin

## Task goals

- Mechanical and magnetic analysis of LQS01
- Engineering design and procurement of support structure and handling, lifting, and tilting tooling
- Assembly, loading, and cool-down to 77 K of
- 850 mm long segment with dummy coils
- Full-length structure with dummy coils
- Assembly, load, and test of LQS01

- 10/27/2008

- Paolo Ferracin

## Magnet designCross-section

- 20 mm thick Al shell
- 4-split iron yoke
- Gap keys and auxiliary bladders
- Holes for tie rods
- Iron pads
- Holes for coil end support and tie rods
- Iron masters
- 2 bladders
- 2 interference keys
- G10 sheet between coil and pad laminations

- 10/27/2008

- Paolo Ferracin

## Magnet design3D components

- 4 shell segments, 0.85 m long
- Yoke laminations, 50 mm thick with 3.4 m long tie rods
- Iron pad laminations, 50 mm thick with 3.4 m long tie rods
- Iron masters, 2 x 1.7 m long
- Easy insertion and removal of coil pack (large clearance)
- Continuous surface
- Pad-yoke alignment
- Improved tolerances

- 10/27/2008

- Paolo Ferracin

## Assembly procedure

- Alignment of pad and yoke laminations with bushings
- Insertion of tie rods
- Pre-tension with piston
- Assembly of 850 mm long segments
- Joining of segments with air pallets
- Alignment by shell-yoke pins
- Insertion of coil-pad sub-assembly with masters

- 10/27/2008

- Paolo Ferracin

## 2D magnetic analysis

- Jc of 2800 A/mm2 (4.2 K, 12 T)
- About 2 T difference between layer 1 and layer 2

- 10/27/2008

- Paolo Ferracin

|  |  |  | Layer 1 | Layer 2 |  |
| --- | --- | --- | --- | --- | --- |
| Temp. | Current | Gradient | Peak field | Peak field | Stored energy |
| K | kA | T/m | T | T | kJ/m |
| 4.5  | 13.76 | 240 | 12.29 | 10.52 | 457 |
| 1.9 | 15.16 | 262 | 13.43 | 11.48 | 559 |

## 3D magnetic analysis

- Peak field in the end located on pole turn, layer 1
- Stainless steel pad 100 mm before end of straight section
- Same peak field in the straight section and end

- 10/27/2008

- Paolo Ferracin

## 2D mechanical analysis

- No gap pole-coil at 240 T/m
- Coil peak stress at 4.5 K
- Pole area, inner radius, layer 1
- 171 MPa
- Coil peak stress at 240 T/m
- Mid-plane, inner radius, layer 1
- 168 MPa
- Key position optimized to minimize coil stress after cool-down and at 240 T/m
- <150 MPa of coil peak stress assuming 220 T/m

- 10/27/2008

- Paolo Ferracin

## 3D mechanical analysis

- No gap pole-coil at 240 T/m
- Axial e.m. force: 471 kN
- Stainless steel rod pre-tension: 88 MPa (178 kN)
- Rod stress at 4.5 K: 239 MPa (484 kN)
- 65 MPa of contact press. after cool-down

- 10/27/2008

- Paolo Ferracin

## Outline

- Task goals
- Magnet design and assembly procedure
- Magnetic and mechanical analysis
- Assembly, loading, and cool-down of a 850 mm long segment with dummy coils
- Assembly of full-length shell-yoke sub-assembly
- Conclusions and next steps

- 10/27/2008

- Paolo Ferracin

## Assembly and loading of 850 mm long segmentStacking pad and yoke laminations

- Yoke rod tension: 330 MPa
- Force on yoke stack: 190 kN

- 10/27/2008

- Paolo Ferracin

## Assembly and loading of 850 mm long segment Insertion of yoke stacks in shell 

- 10/27/2008

- Paolo Ferracin

## Assembly and loading of 850 mm long segmentAssembly of dummy coil pack

- 10/27/2008

- Paolo Ferracin

## Assembly and loading of 850 mm long segmentLoading and insertion in the cryostat

- 10/27/2008

- Paolo Ferracin

## Cool-down to 77 K of 850 mm long segment

- Shell stress at 77 K
- Azimuthal:  +138 ± 6 MPa
- Axial: +41 ± 13 MPa

- Dummy coil stress at77K
- Azimuthal: -231 ± 23 MPa
- Axial: +74 ± 7 MPa

- 10/27/2008

- Paolo Ferracin

## Assembly of full-length structureSection 1 and 2 before joining operation

- 10/27/2008

- Paolo Ferracin

## Assembly of full-length structureRemoval of 850 mm long yoke tie rods

- 10/27/2008

- Paolo Ferracin

## Assembly of full-length structurePreparation of alignment pins and bushings

- 10/27/2008

- Paolo Ferracin

## Assembly of full-length structureJoining operation of 2 segments (I)

- 10/27/2008

- Paolo Ferracin

## Assembly of full-length structure Joining operation of 2 segments (II)

- 10/27/2008

- Paolo Ferracin

## Assembly of full-length structureInsertion-tensioning of 1.7 m long yoke tie rods

- 10/27/2008

- Paolo Ferracin

## Assembly of full-length structureAssembly of 1.7 m long dummy coil pack

- 10/27/2008

- Paolo Ferracin

## Assembly of full-length structurePre-loading and insertion of 1.7 m long gap keys

- 10/27/2008

- Paolo Ferracin

## Assembly of full-length structureAssembly of second segment pair

- 10/27/2008

- Paolo Ferracin

## Assembly of full-length structureJoining operation of 2 segment pairs

- 10/27/2008

- Paolo Ferracin

- Yoke rod tension: 330 MPa
- Compressive force: 760 kN

## Assembly of full-length structure3.4 m long yoke-shell sub-assembly

- 10/27/2008

- Paolo Ferracin

## Assembly of full-length structure3.4 m long yoke-shell sub-assembly

- 10/27/2008

- Paolo Ferracin

## Outline

- Task goals
- Magnet design and assembly procedure
- Magnetic and mechanical analysis
- Assembly, loading, and cool-down of a 850 mm long segment with dummy coils
- Assembly of full-length shell-yoke sub-assembly
- Conclusions and next steps

- 10/27/2008

- Paolo Ferracin

## Conclusions

- 3.7 m long LQ shell-based support structure (LQS) designed, analyzed with 2D/3D magnetic/mechanical models, and procured
- Coil supported (no gaps expected) up to 240 T/m
- 850 mm long segment assembled, loaded, and cooled-down to 77 K with dummy coils
- Strain gauge results consistent with expectations
- Loading with bladders of a 1.7 m long structure performed
- Same operation as for full-length structure
- Full-length shell-yoke sub-assembly completed
- Successful implementation of procedure based on short segments

- 10/27/2008

- Paolo Ferracin

## Next steps (I)

- Assembly of a full-length dummy coil pack
- Assembly and loading of a full-length structure with dummy coils (LQSD)
- Bladder operation
- Pressure sensitive film test
- Pre-tensioning of coil axial support system

- 10/27/2008

- Paolo Ferracin

## Next steps (II)

- 10/27/2008

- Paolo Ferracin

- Lifting/tilting tooling
- Complete procurement
- Test components
- Assembly around LQSD structure
- Shipment LQSD from LBNL to FNAL
- Tilting and insertion in the cryostat
- Cool-down test of LQSD and analysis
- Shipment LQSD from FNAL to LBNL
- Disassembly of LQSD

## Next steps (III)

- Tooling for coil-pad assembly
- Complete design and procurement
- Test with practice coils
- Assembly and loading of LQS01
- Bladder and axial loading operations
- Connection of all instrumentation to connectors mounted on the shell (lead end)
- Assembly of lifting/tilting tooling
- Shipment of LQS01 from LBNL to FNAL
- Tilting and insertion of LQS01 in the cryostat
- Test of LQS01

- 10/27/2008

- Paolo Ferracin