# Presentation: 811394

## TQC01-3  Plans R. Bossert

***bnl - fnal- lbnl - slac***

_**US LHC Accelerator Research Program**_

- LARP Collaboration Meeting
- October 5-6, 2005

## TQC01-3 objectives

- TQC01-3 are technological quadrupole models based on the *collar-yoke-skin mechanical structure*
- Design goals
- Achieve Gmax>210 T/m.
- Fabricate, test and evaluate 2-layer shell-type coil design without internal interlayer splices
- Fabricate, test and evaluate mechanical structures based on collar-yoke-skin support
- Develop and evaluate coil fabrication and magnet assembly technologies
- Performance study:
- magnet quench performance: training, re-training, SSL
- field quality: geometrical harmonics, coil magnetization, iron saturation, alignment, field quality correction
- quench protection: conductor parameters, quench heaters
- operating margin: thermal model with mid-plane heaters
- Compare TQC and TQS designs, technology and performance parameters

## TQ coil

**Coil:**
**2-layer shell-type**
**Inner-layer wedges**
**Inner-layer pole glued into the coil**
**Cable:**
**Strand – Nb3Sn, 0.7 mm**
**Number of strands – 27**
**Keystone angle – 1 deg**
**Width – 10.05 mm**
**Thickness – 1.26 mm**
**Insulation: 0.125 mm S2-glass sleeve**
**Identical to TQS coils.**

## TQC design approach

- TQC design is based on the MQXB mechanical structure (collar, yoke, skin, end plate, etc.).
- Two stages
- 2-layer coil with thick collar
- 3-layer coil with thin collar
- TQC uses available coil winding and curing tooling (winding tables, mandrels, presses, etc.).
- Mechanical structure, tooling and infrastructure exist for 1-2 m long and up to 6 m long magnets.

- MQXB cross-section.

## TQC mechanical structure

- Modified MQXB collar blocks with outer-layer poles for coil alignment. Inner-layer poles are glued into the coil.
- Radial yoke cut per lamination to provide symmetrical load.
- Control spacers for collared coil alignment and yoke motion control.
- Four shims in the midplanes to control coil-yoke interference.
- 12 mm thick stainless steel skin.
- Mechanical structure and coil pre-stress will be studied and optimized using short (~30 cm) mechanical model.

- TQ2a cross-section

## TQC parameters

## TQC01 Objectives 

-  Design, fabricate and test a 1m long, 2 layer, 90mm Nb3Sn quadrupole model using mechanical support structure based on 25mm thick SS collars.  Compare magnet performance with the design parameters.
-  Provide input for a consistent comparison between the properties of a collar-based structure and an aluminum shell-based structure (TQS model).
-  Use the same coil design for both TQS and TQC models.

## TQC01 Schedule and Status

_**FY05**_:
- Design of cable, coil, and tooling: 	FNAL+LBNL;	01/15/2005  Complete
- Fabricate and insulate practice cable: 	LBNL; 	  	04/15/2005  Complete
- Procure coil fabrication tooling/parts: 	FNAL; 	  	05/01/2005  Complete
- Procure mech model parts:	 	FNAL; 	  	07/15/2005  Complete
- Wind & Cure 2 practice coils: 		FNAL+LBNL;  	08/01/2005  Complete
- React & impregnate 2 practice coils:	FNAL;		09/15/2005  Complete
_**FY06:**_
- Assemble and test mechanical model: 	FNAL; 	  	11/10/2005
- Wind/cure coils: 			FNAL;		12/20/2005
- React/impregnate coils:		FNAL; 		02/10/2006
- Assemble magnet:			FNAL;		03/17/2006
- Test magnet: 			BNL;		05/05/2006

## TQC01 Budget 

|  | LARP |  | Base Program |  | Total |
| --- | --- | --- | --- | --- | --- |
|  | FY05 | FY06 | FY05 | FY06 |  |
| FNAL | 150 | 389 | 192 | 0 | 731 |
| LBNL | 20 | 160 | 78 | 0 | 258 |
| BNL | 27 | 67 | 0 | 0 | 94 |
| Total | 197 | 616 | 270 | 0 | 1083 |

- Applied 50% of shared TQS01/C01 effort. Strand purchase to return to FNAL not included. Cabling not included.

- (in thousands of dollars)

## TQC02 Objectives 

-  Design, fabricate and test a 2nd 1-m long, 2-layer, 90-mm Nb3Sn quadrupole model using mechanical support structure based on 25-mm thick SS collar. Compare magnet performance with the design parameters and the performance of TQC01.  Increase the statistical “database” for TQ short models.
-  Provide input for a consistent comparison between the properties of a collar-based structure and an Aluminum shell-based structure (TQS models).
-  Refine design features based on construction experience and/or testing of TQC01.
-  Incorporate RRP strand in TQ coils and structure.

## TQC02 Schedule

_**FY06 **_
- Conductor available: 			FNAL+LBNL:	11/01/2005
- Fabricate and insulate cable: 		LBNL: 	  	01/31/2006
- Coil winding complete:			FNAL:		05/01/2006
- Coil impregnation complete: 	 	FNAL: 	  	05/15/2006
- Assembly complete: 			FNAL:  		06/20/2006
- Testing and analysis complete: 		FNAL: 	  	08/20/2006

## TQC02 Budget

|  | LARP |  | Base Program |  | Total |
| --- | --- | --- | --- | --- | --- |
|  | FY06 | FY07 | FY06 | FY07 |  |
| FNAL | 505 | 0 | 0 | 0 | 505 |
| LBNL | 25 | 0 | 0 | 0 | 25 |
| BNL | 0 | 0 | 0 | 0 | 0 |
| Total | 530 | 0 | 0 | 0 | 530 |

- (in thousands of dollars)

- Cabling not included.

## TQC03 Objectives

-  Design, fabricate and test a 3rd 1-m long, 2-layer, 90-mm Nb3Sn quadrupole model using mechanical support structure based on 25-mm thick SS collar. Compare magnet performance with the design parameters and the performance of TQC01 and TQC02.  Increase the statistical “database” for TQ short models.
-  Provide input for a consistent comparison between the properties of a collar-based structure and an Aluminum shell-based structure (TQS models).
-  Refine design features based on construction experience and/or testing of TQC01/2.  Possibly redesign coil cross-section or cable configuration.
-  Incorporate new RRP strand in TQ coils and structure.

## TQC03 Schedule

_**FY06**_
- TQC01 and TQS01 analysis complete: 	FNAL+LBNL:	06/01/2006
- Design optimization: 			FNAL+LBNL:   	07/15/2006
- Cable fabricated and insulated:		LBNL:		08/04/2006
- Practice coils wind/cure: 			LBNL: 		09/15/2006
_**FY07**_
- Practice coils react/pot: 			FNAL:  		10/15/2006
- Wind/cure coils: 				LBNL:		01/20/2007
- React/impregnate coils:			FNAL: 		02/20/2007
- Assemble magnet:			FNAL:		 04/01/2007
- Testing and analysis complete:		BNL:		06/01/2007

## TQC03 Budget

|  | LARP |  | Base Program |  | Total |
| --- | --- | --- | --- | --- | --- |
|  | FY06 | FY07 | FY06 | FY07 |  |
| FNAL | 153 | 374 | 0 | 0 | 527 |
| LBNL | 94 | 125 | 0 | 0 | 219 |
| BNL | 0 | 48 | 0 | 0 | 48 |
| Total | 247 | 547 | 0 | 0 | 794 |

- (in thousands of dollars)

- Applied 50% of shared TQS03/C03 effort. Cabling not included.

## TQ Current Status

-  The TQ coil manufacturing has been very successful to date.  No major delays or problems have occurred. LBL and FNAL have successfully collaborated on their completion.

-  4 practice coils have been manufactured.

## TQ Current Status

-  Some minor issues were resolved during the practice coil manufacturing process:

-  Gaps between turns and end parts appeared on practice coil #1 due to the necessity of grinding parts to place them onto the uncompressed coil during winding, a common practice when making Nb3Sn coils.   This problem has been solved by cutting slots into certain end parts to make them more flexible.

-  Experiments with longitudinal gaps needed for differential expansion of pole parts vs. coils were completed.  Gaps have been established at 2.5mm.
-  Ramp area between inner and outer coils deformed during curing on early practice coils.  New tooling, incorporated in practice coil #4, alleviated stresses in this area and eliminated the deformations.

-  Some instances of de-cabling during winding have been controlled with winding techniques, primarily reducing winding tension at critical moments, adding a 360 degree twist between the cable tensioning device and the coil during winding, and changing the system which measures tension, allowing the cable to take a straight path directly from the tensioner to the coil, rather than passing through a series of rollers.

## Current Status

-  The first set of practice coils were reacted and impregnated at Fermilab. Impregnation looks good, techniques are documented.

-  The remaining two are currently being reacted, and will be impregnated, at LBNL.

## Current Status

-  Work on the TQC mechanical model has begun, with warm and cold test using an aluminum tube to replicate the coils.  The model will now be built with the first two impregnated practice coils, cut in half to allow 4 pieces of straight section to be installed.  When testing is done at FNAL, the coils will be sent to LBNL to be used in a TQS mechanical model with the second two practice coils.

## Current Status

-  Coils for TQS01 are currently being fabricated.  The first two coils are complete, with the third and fourth scheduled to closely follow.  Coil winding is on schedule.

-  7 UL of cable for TQS01/TQC01 are insulated and on hand at FNAL.  The remaining 3 UL have been fabricated by LBNL.  One UL (for TQS01) will be insulated and shipped by next week.  The remaining two will be insulated when the material arrives.