JHF Horn construction status
and K2K horn experience
YAMANOI Yutaka (KEK)•K2K Horn system•The operation result of K2K Horns–Trivial troubles (2002-2003)•Status of JHF Horns•Basic parameters–Mechanism and Merit of FSW–

Concrete stuffing strip line–

The pulse currents test by the power supply of K2K Horn

•Schedule•

SummaryK2K Horn system
Target & First HORN
Second HORN

1.05°Beam•••

Pulse Current•••

Built-in production target (φ30mm)(Blue) Removable train:-A distance between horns is about 8.06 m.
(Green) Adjustment table:-decline to Super-Kamiokande with 1.05°-Accuracy is equal to about 0.04 mrad.
Operation current 250k Amp at both horns
High pulsed current 2.5ms width, 2.18s cycle
Total Joule’s heat=7740 kcal/hThe operation result of K2K Horns
14.E+06
第１－７号機
第２ー３号機

1st Horn

12.E+06
2nd Horn

10.E+06

08.E+06

06.E+06

第２－１号機Run2001-02

第１－４号機
φ３０

Run1999
04.E+06

Now

第２－２号機Run2000

第１－３号機
φ２５

第１－８号機第２－４号機第１－５号機φ２５

第１－２号機
φ２０'04/03'04/01'03/11'03/09'03/07'03/05'03/03'03/01'02/11'02/09'02/07'02/05'02/03'01/11'01/09'01/07'01/05'01/03

第１－８号機

'01/01'00/11'00/09'00/05'00/03'00/01'99/11'99/09'99/07'99/05'99/03'99/0100.E+00'00/07

第１－６号機parba
cap'02/0102.E+06

Run2002-03

K2K Horns Logbook (1) Water level gauge
January 10, 2003
After underwater for 4years
The water level gauge
made from Teflon broke.

Radioactive dirty water

Eliminator unit

Reservoir,Pump unit(2) Canned-Rotor Pump

The swirl pump of a multi-stage typeApril 4, 2003
Water leaked from the mechanical seal of aswirl pump. The pump was changed into thecanned-rotor pump.

A canned-rotor pump is no liquid leak and low noise
without a mechanical seal and a cooling fan.

(3) Harness of a sticking-by-pressure terminal
Jun 06, 2003
After 25.8 million operations
The harness of a cable shook and broke.

shake

2nd Horn
Transformer

1st Horn
Transformer

Status of JHF Horns•Horn system optical design (Ichikawa)•Target station design for Target and Horns (Yamada)•Basic parameters (NBI03 version)•High priority subjects- Consideration to recycle of K2K equipments- Welding technology for making a inner conductor- Design to installation to Target station with He-tight- Durability test by the power supply of K2K horn

•Construction ScheduleBasic parameters
Horn #1
Proton beam energy

0.55 µH
118µΩ

3.6s
5 µs
300 kA
0.46µH100µΩ
50.48µH
90µΩ

2000
2500

φ1400

φ900

φ800

0.31ms
1.1kW
10kW
1.0mF
5400V

φ470

φ360

φ56

Horn #33x1014 ppp

Beam I ntensity
Ring cycle
Pulse lengthHorn current peakI nductanceResistanceTransformer ratioPeak risetime
Joule heating
Radiation Heating
Capacitance
Charging v oltage

1500Horn #250 GeV

1st Horn
300kA

Thickness 3mm
D 56mmD 360mm

TARGETt 3.6mm

t 3.6mm
R 75mm

30 mm

250mm
1500 mm

A6061、or (A2219, A7003, A5083)

2nd Horn
300kA

Thickness 3mm

D900mm

D60mm

D470mm

30mm

2000 mm3rd Horn
300kA

Thickness 3mm

D800mm

D100mm

30mm

2500mm

D1400mm

Comparison with the welding method
Proofstress(A6061)

Heat
distortion

Workability

Cost

Merit/Demerit△A welding pretreatment isrequired. The large equipment isrequired. Triming is needed afterwelding.

Laser Beam Welding○〜 85%

Electron Beam Welding○〜 85%◎○△The vacuum chamber containing ahorn is needed. Triming is needed
after welding.

Friction Stir Welding○〜 80%◎◎○New technology. No-Trimming
after welding. Easy to adjust thelength. ～ 0.3mm

MIG (metel inert gas)
Welding△〜 60%△○◎

Welding distortion is large. Thereis variation in the quality by skill.

TIG (tungsten inertgas) Welding△〜 60%△○◎

Welding distortion is large. Thereis variation in the quality by skill.

◎○Mechanism and Merit of FSW (Friction Stir Welding)

FSW

HITACHI, Ltd.

• Invented at TWI(1991)• Applied to space rocket, train body
• Very low distortion-Good dimensional stability
and repeatability• Fully mechanical process-No fume, porosity or spatter• Excellent mechanical/metallurgicalproperties• Very cost effective

R = P min / P max = 0.1

LOAD
P0tim
e-2.25kN

P min(σ min)-22.5kN

P max(σ max)

Result（ ×10-6）400

θ-axisMax. Distortion ε200

270 deg0-200-400-600-800z-axis-1000
1.0E+00 1.0E+01 1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08

Number of repetition times N

It carried out 1.09x10^7 times by the maximum load 22.5kN.
The damage by repetition fatigue was not found.

90 degTarget Station (Y.YAMADA)To reduce NOx and Tritium in the target station> The He gas is filled in TS.

Tr.

Tr.

Tr.

HeConcrete stuffing strip line

Surface treatment (t 25μm hard anodic oxide
coating + sealing)
Withstand voltage
Heat resistanceCorrosion resistance

2.8kV-2x1010ohm
300 degrees C-4hrSalt spray test OK(ASTM-B-117)

The pulse currents test by the power supply of K2K Horn

Power supply of K2K Horn
Transformer

Primarycircuit
20 turns

１次コイル
４回路分
並列接続

Secondarycircuit
2 turnsx 4 circuits

２次コイル・４回路分•JHF Inner conductor+ K2K Outer conductor•Transformer ratio: 10 -> 5250kA -> 300kA(Max.500kA)
The pulse test will be begunin spring of 2004.

Horns Construction Schedule
Fiscal year

2003(H15)47 10

K2K Horns

2004(H16)
1Running

47 102005(H17)
1Production of Horn #1
Install of peripheral equipment

7 10147 102007(H19)147 102008(H20)
1Running

Remake of K2K power supply #1,#2
Design of JHF Horns and TS42006(H18)

power supply
Designfull-size
peripheral

Durability test of JHF Horn #1

test

Combines with a target
Production of Horn #2

full-size

Durability test of JHF Horn #2
Production of Horn #3
Durability test of JHF Horn #3

test
full-size
test

Production of new power supply #3
Production of 3 Horns
Construction of TS
Preparation of peripheral equipment
Install in TS
Commissioning

power supply
full-size
Construction of TS47 101

Summary••••Now our K2K horns are very stable.
We should pay attention more and more toperipherals.
Now we design JHF Horns and Target station.
I want to excitation tests about full size horn and all
peripherals in the real situation as soon as possible.