# Presentation: 384569

## Plans for Future SRF Infrastructure

- Shekhar Mishra
- ILC Program
- Fermilab

## Vision: SRF FY08-09 and Beyond

- A new approach to managing the ILC R&D and US ILC Program has been proposed by the American Regional Team of the Global Design Effort (ART-ILC-GDE) and US Regional Team (USRT)
- Develop a national program for ILC
- A consortium of U.S. laboratories and universities already involved in SRF R&D will be the nucleus of this effort.
- The collaboration will, in close communication with the ART- ILC-GDE, ILC R&D Board, USRT and Major Laboratories (Fermilab and SLAC) managements would
- establish goals
- develop a technical and resource management plan to reach those goals.
- The proposed plan has tried to make a balance between the scope and resources.
- “Credible” and “Qualified to be a Host”:  Invest in significant SRF infrastructure
- Strong international collaboration with DESY, the TESLA Technology collaboration (TTC), INFN, KEK, STF collaborations and others will be important.

- Talk at AAC

- 12/4/06

## International SRF Collaboration

- US SRF Collaboration
-  Fermilab
-  Jlab
-  Cornell
-  ANL
-  LANL
-  MSU
-  SLAC
-  Universities (UPenn, IIT, NIU, NW...)

-  DESY
-  KEK
-  INFN
-  ORSAY

- Developing SRF Collaboration
-  India
-  China
-  Korea
-  .....

- S. Mishra (FNAL)
- H. Padamsee (Cornell) & SRF collaboration
- J. Mammoser (JLab)
- M. Kelly (ANL)

- R. Kephart, FNAL, Regional Interest & WBS 7
- S. Ozaki, BNL, Regional Interest
- T. Tajima, LANL
- R. York, MSU
- Nigel Lockyer, UPenn, University Groups
- G. Gollin, UIUC, University Groups

- Co-ordinate with Main Linac Accelerator Physics and RF
- P. Tenenbaum (SLAC) and  N. Solyak (FNAL)
- C. Adolphsen (SALC) and S. Nagaitsev (FNAL)

- Talk at AAC

- 12/4/06

## Overview: 3 Major Areas of SRF Work

- Support S0, S1 and S2 goals (as discussed in GDE Task Forces)
- Demonstrate ILC technology
- Work with GDE, work with TTC
- Install sufficient infra-structure to support activities
- Advance industrial capability for SRF in the US region to improve our readiness for ILC (as discussed in Regional Interest Panel)
- US labs and industry need to gain command of main linac technology (core competency)
- Industry and labs work closely together
- Carry out key ACD R&D items (as outlined in the BCD)
- GDE  wants a “forward looking” approach
- Improve ILC performance, reduce cost

- Talk at AAC

- 12/4/06

## Technical Goals

- The technical goals are consistent with the ILC-GDE priorities as proposed by the S0, S1 and S2 Task Forces and the US Regional priorities (Ozaki Panel).
- Develop cavity processing parameters for a reproducible cavity gradient of 35 MV/m; improve the yield of 9-cell cavities for gradient of 35 MV/m in vertical tests (S0.1).  Carry out parallel/coupled R&D on cavity material, fabrication, and processing to identify paths to success (S0.2).
- Assemble and test one or more cryomodules with average gradient > 31.5 MV/m (S1).
- Build and test one or more ILC rf units at ILC beam parameters, high gradient, and full pulse rep rate (S2.1).
- Develop plans for an ILC Main Linac System Test consisting of several rf units (S2.2).
- Strengthen U.S. SRF technical capabilities and prepare the U.S. with the infrastructure, expertise and industrial capabilities necessary to host the machine.

- Talk at AAC

- 12/4/06

## Cavity Gradient: 35 MV/m

- At present, there is good proof-of-principle that 9-cell cavities reach gradients of 35 – 40 MV/m after applying the best preparation procedures
- Electro-polishing (EP),
- High Pressure Rinsing (HPR)
- Baking at 120 C.
- DESY has tested (~10) cavities with gradients of 35 - 40 MV/m,
- Yield is less than 0.5,
- Gradient spread is large ( 25%)
- Average number of preparations and test cycles per cavity is three.
- Cavity fabrication and processing R&D is needed to achieve an overall yield > 80% in the first test of cavities and 95% ultimate in two tests for cavities
- Limited by inadequate preparation.

- Talk at AAC

- 12/4/06

## Yield Improvement: 35 MV/m

- The yield improvements would come in a few stages
- Input from R&D activities becomes incorporated into the 9-cell preparation
- Testing batches for each stage.
- Dramatic improvement in yield and spread will require coupled R&D programs in parallel to large scale testing of 9-cell cavities.
- Basic R&D on the preparation recipes
- Materials R&D
- Diagnostics on EP, HPR, VTS systems
- Multi-cell tests with full diagnostics
- Single cells preparation/tests
- Present Limiting Factors:
- Field emission
- Quench
- Hydrogen initiated Q-disease.
- Existing Procedure needs optimization and we need to explore any promising procedures that reduces these effects.  Some examples are:
- Improved methods of final rinsing
- New final rinsing agents
- Stringent control of cleanliness during assembly
- Processing field emission with high pulsed power RF.

- Talk at AAC

- 12/4/06

## Gradient R&D: Scope Details

- S0 has two main parts (with subdivisions)
- S0.1: Tight loop to improve “final preparation” yield
- 1a. 9 best cavities globally  x 3 tests each, cross calibrate regions (may       need to start with 15-20 cavities)
- 1b. Parallel/coupled R&D to improve yield (1-Cell Program, Study of failed cavity, Materail R&D, etc.)
- 1a’. Repeat 3 cycles on 9 cavities with improved process
- S0.2; Production-like activities to determine overall yield for cavity materials, fabrication and full cavity processing
- 2a. First batch of about 36 cavities globally (12 US Cavities)
- 2b. Second batch of about 150 cavities globally (50 US Cavities)
- Using an “optimistic model” for increasing production and process yield, USRT is considering the availability of 32, 96 and 96 good cavities during 2008, 2009, and 2010.
- This will require more cavities to be ordered and processed

- Talk at AAC

- 12/4/06

## Cryomodule and RF Unit R&D: S1 and S2

- S1 Goal:
- Prepare and test 3 or more ILC cryomodules
- Demonstrate average gradient > 31.5 MV/m
- S2 Goal:
- Small scale Test Facilities in all 3 Regions with 1 – 2 RF Units
- In American Region the proposal is two build 2 RF Units
- 1 learning RF unit with the goals of engineering development, cost reduction and initial industrial involvement
-  Plus 1 ILC RF unit with 31.5 MV/m operating gradient
- A String of several RF units ( number and models under discussion)
- Ideally S0.2 and S1 should interface with S2
- Prepare the needed number of cavities in S0.2 for S1 and S2

- Talk at AAC

- 12/4/06

## Production Model: LHC vs. ILC

- The LHC requires 1200 cryomodules (15 m long) as compared to the ILC’s 2000 modules (12 m long).  (Superconducting Magnet a established Technology)
- After design and modeling work at CERN
- 3 prototype coils were built in industry and modules assembled and tested at CERN.
- Prior to launching a large “pre-construction series,”
- 9 modules (3 per vendor) assembled at CERN using facilities installed at CERN.
- Vendors then manufactured
- Total of ~20 modules (7 per vendor).
- ~6 of these were fully tested (2 per vendor) before starting the pre-construction series.
- Total of 32 modules were prepared by the CERN/industrial collaboration before launching the pre-series.
- The “pre-construction” series consisting of 90 modules by 3 vendors was successfully finished over a 2 year period.
- Upon completing the pre-series, CERN launched the final construction series of the remaining 1100 modules.

- Talk at AAC

- 12/4/06

## Cryomodule: US Infrastructure Development

- These combined activities for Cavity and Cryomodule would demonstrate that ILC Main Linac Technology
- is prepared for a multi-billion dollar project,
- that regional institutions have gained adequate command of the technology,
- that the regional industrial capability exists for the large scale, big expense components for ILC
- cavities, cryomodules, refrigeration, and RF power.
- Industrial involvement would be encouraged in early cryomodule activities for future vendor training and qualification.
- Industrial personnel could assemble cryomodule using the infrastructure set up at the laboratories.
- Building significant number (~28) of cryomodules would better prepare industry to launch construction.
- The staged approach (laboratory and Industry working together) would qualify industry to build modules, estimate costs, and finally lower costs in larger production stages during construction.

- Talk at AAC

- 12/4/06

## Infrastructure for Cavity and Cryomodule Fabrication, Processing and Testing

- Bare cavity production (3-4 depending on number of vendors to develop)
- Fabrication facilities (e.g. Electron beam welders)
- Buffered Chemical Polish facilities (BCP) for cavity parts pre-welding
- Cavity Processing
- Tuning for field flatness
- Surface Processing (Tumbling, BCP and Electro Polishing)
- Ultra clean H20 & High Pressure Rinse systems
- Furnace for 600 – 800 C bake (removal of H)
- Vertical Test facilities (Cryogenics + low power RF)
- Cavity Dressing Facilities (cryostat, tuner, coupler)
- Class-100 clean room
- Horizontal cavity test & Coupler test facilities (RF pulsed power)
- String Assembly Facilities
- Large class-100 clean rooms, Large module assembly fixtures
- Class-10 enclosures for cavity inner connects
- Cryo-module test facilities
- Cryogenics, pulsed RF power, LLRF, controls, shielding, etc.
- Beam tests  electron source (to test RF units)

- Talk at AAC

- 12/4/06

## Model: Processing and Testing Infrastructure 

**Degrease &  EP 80 um (3 days)**
**HPR 1 day**
**Drying  1 day**
**H-removal, 600 – 800 C (3 days)**
**Tune field flat (1 day)**
**EP 10 um (1 day)**
**HPR (1 day)**
**dry (1 day)**
**First stage assembly & HPR (1 day)**
**Dry 1 day**
**Final assembly to bake stand, evacuation (1 day)**
**120 C on bake stand (2 days)**
**Assembly to test stand (1 day)**
**Cold test, warm up (3 days)**
**Total 21 days (4 weeks)**
**Test set-up has maximum 4-day, rate limiting time**
**Assume one set-up each per facility**
**Max cycles = 5 per month (20 days) = 60 per year**
**Down time and maintenance time may reduce this**
**Calculation Estimates: 50 per year max**
**Jlab estimates : 40/year**

- A R&D and Production Model

- Talk at AAC

- 12/4/06

## Present: US SRF Infrastructure Strength

- Limited cavity fabrication capability in US industry
- One US company (AES) fabricating SRF cavity
- Two new companies (Niowave and Roark) being developed
- European Industry much advanced in ILC cavity fabrication
- Cavity Processing and Vertical Testing R&D Facility
- Jlab (30 FY07, 40 FY08, 50 FY09) cycles/yr
- ANL/FNAL ( 50 FY08, 60 FY09) cycles/yr
- Cornell 12 cycles/yr
- VTS @FNAL 70 cycles/yr (FY07)
- Significant capacity will be used by supporting R&D Program
- Process development
- Single cell Processing
- Horizontal Test Stand
- FNAL 24 cavities/yr
- Cavity Dressing and Cryomodule Assembly
- FNAL 12/yr (FY07)

- Talk at AAC

- 12/4/06

**Notes:**
(These facilities are very important for our R&D. These have a single line of processing and no Redundancy in the system.)

## Scope: US SRF Infrastructure

- Increased cavity fabrication capability in US industry
- Electron Beam Welder
- Automated Cavity Tuning
- 100+ Cavity/yr ( by FY09)
- Processing and Vertical Testing (Pre-Production Facility, existing technology with industry redundancy)
- 100+ Cavity/yr (by FY09)
- Horizontal Test Stand
- Additional 48 Test/yr (Maximum Capacity needed)
- Cryomodule Test without beam
- Cryomodule Test Stand (1 by FY10)
- RF Unit Assembly and test without and with beam

- Talk at AAC

- 12/4/06

## Cavity Processing and Testing

- The present US model of using distributed Cavity Processing and testing infrastructure is an ideal way to get started with very limited resources to make significant progress towards the ILC R&D goals.
- The production of high-performance SRF cavities will require state-of-the-art surface preparation.
- An integrated facility will allow significant improvement of the current preparation steps towards an industrial production-like level with a large enough throughput (~100 cavities/yr)
- We have proposed build such a facility at Fermilab

- Talk at AAC

- 12/4/06

## Cavity and Cryomodule Infrastructure

**European Infrastructure Proposal**

- Talk at AAC

- 12/4/06

## Cavity Preparation Infrastructure

- The proposed infrastructure will improve over the existing infrastructures
- Present infrastructures are single-line processing R&D infrastructure
- Failure in one process chain leads to unacceptable delay in schedule
- New Infrastructure will have
- All cavity processing under one clean environment
- Redundancy in layout
- Modularized for maintainability and flexibility
- Flexibility: Implementing change in the overall production scheme
- Quality Assurance and control process
- Available for use for other projects

- Talk at AAC

- 12/4/06

## DESY Infrastructure Downtime

- Success Oriented Planning: Several months of down time has not been considered.

- Talk at AAC

- 12/4/06

## Cavity Preparation Infrastructure

**Already at MP9**

**European Infrastructure Proposal**

- Talk at AAC

- 12/4/06

## Cryomodule Test Stand

-  US ILC R&D proposed to build 10’s of cryomodule before production.
-  The ILCTA_NML plan is to test first 5 Cryomodule.
-  After that it will be dedicated for the RF Unit studies.
-  We have proposed to build a Cryomodule test stand at ILCTA_ME next to the Horizontal Test Stand with the goal of having it operation by FY10.
-  We need to collaborate with DESY on this project.

- DESY’s Cryo Module Test Bench

- Talk at AAC

- 12/4/06

## HTS and VTS

- Fermilab is in process of installing a Horizontal and Vertical Test Stand with the initial capacity of
- 70 (140) cavity test/yr in Vertical test stand
- 12-24 cavity test/yr in Horizontal test stand
- Additional Vertical testing capacity will be needed for increased number of cavities beyond FY09.
- We have proposed to add two more pits to the vertical test stand with shared cryogenics and RF infrastructure
- An additional Horizontal Test Stand with two cavities capability will be need to test a maximum of 5% of the ILC cavities.
- This could be used for development of other hardware like RF control by having multiple cavities.

- Talk at AAC

- 12/4/06

## Jlab R&D Program

- R&D Program
- Processing and Vertical Testing of 9 Cell Cavity for S0 program
- Single Cell R&D to improve the Processing
- Field Emission studies for tracking the contamination
- ACD: LL Shape Cavities, Large Grain and Single Crystal
- Jlab Infrastructure Upgrade
- Jlab has already commissioned a electro-polishing and vertical testing for ILC cavities
- Development of Field emission studies
- Incremental upgrade and maintenance of the facility

- Talk at AAC

- 12/4/06

## Cornell R&D Program

- R&D Program
- Electro-polishing and testing of 9-cell cavities (S0)
- Explore basic parameters for HPP with 9-cell ILC Cavity
- Process and test two 9-cell re-entrant cavities (0.5 FTE)
- Fine grain with EP, large-grain with BCP
- Cornell SRF Infrastructure Upgrade
- Vertical EP
- RF power source 300 – 400 Watt
- Smaller diameter vertical test dewar

- Talk at AAC

- 12/4/06

## ANL R&D Program

- Electro-polish ILC cavities for S0
- Develop and improve processing parameters
- Optimize existing EP hardware/Interface with U.S. EP vendors/develop and optimize hardware suitable for large-scale EP
- ANL SRF Infrastructure Upgrade:
- Finish and commission the new EP system
- Install new HPR system
- Installation of a PLC-based control system for EP

- Talk at AAC

- 12/4/06

## MSU and LANL R&D Program

- MSU R&D Program:
- Cavity Autopsy (Yield Improvement)
- Single Cell Cavity (R&D)
- Advanced Cavity and Material Science studies  (R&D)
- MSU SRF Infrastructure Upgrade:
- Upgrade ultra-pure water and high pressure rinse
- Nine-cell structure vertical test dewar
- LANL R&D Program:
- Cavity Autopsy (Yield Improvement)
- LANL SRF Infrastructure Upgrade:
- Re establish cavity testing at LANL
- 1.3 GHz Power Amplifier
- Thermometry (provided by Fermilab)

- Talk at AAC

- 12/4/06

## Fermilab Program

- Order Cavity and Cryomodule parts
- Material QC and R&D
- Vertical test processed cavities at collaborating laboratories
- Dress cavities with Power Coupler, Tuner etc.
- High Power test of dressed cavities
- Assemble and test cryomodule
- Fermilab New Infrastructure Development
- Design and Build one Cryomodule Test Stand
- Design and build one Cavity Processing Facility
- Upgrade to VTS and HTS

- Talk at AAC

- 12/4/06

## SRF Funding

|  | Request
08 | Request
09 | GDE Recom..
08 | GDE Recom..
08 |
| --- | --- | --- | --- | --- |
| Cavities & Cryomodules, for S0, S1 and Regional Interest | 
32.2 | 
54.5 | 
24 | 
23 |
| Basic R&D to improve performance, incl ACD activities | 4.3 | 3.4 | 4 | 3 |
| Cavity, CM and RF Unit Infrastructure | 37.7 | 17.7 | 18 | 20 |
| Grand Total
 | 74.2 | 75.6 | 46 | 46 |

**The WBS Managers are working on a slightly modified $50M Program**

- Talk at AAC

- 12/4/06

## $50M Funding Impact

- Significantly reduces the Cavity and Cryomodule program
- Industrial development
- Delay the cavity processing infrastructure to after FY10
- Small delay in the RF Unit test infrastructure
- Eliminated upgrade to the Vertical and Horizontal test facilities.

- Talk at AAC

- 12/4/06

## Summary

- The Main Linac Cavity and Cryomodule R&D program and Infrastructure development as presented would
- Impact and contribute toward the critical ILC R&D as proposed by ILC Task Forces
- Build a minimal facility at Fermilab
- Train people in SRF at Fermilab
- Get the US industry involved from initial phase
- Position US to be a “creditable” and “qualified host”
- We request a strong support for the full program.

- Talk at AAC

- 12/4/06