hwr cavity parting and fabrication - indico-fnal (indico) · 2012-03-04 · considerations for...
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HWR Cavity Parting and Fabrication
Design and Fabrication of a 162.5 MHz HWR cryomodule for Project X
Speaker: Mike Kelly
March 5, 2012
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Considerations for Fabrication and Processing
1. Niobium material and parting
2. Forming, cutting machining
3. Tuning
4. Surface processing – S. Gerbick
5. Testing
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ANL SRF Group
Quality Control
Coordination
Nb procurement,
Mechanical & EM
design
Chemistry
Clean processing &
assembly
Testing
ANL Shops
Adron
Wire EDM niobium
cutting
AES
Sciaky
Roark
Niobium tooling and forming –
FEA
Electron beam welding
Meyer Tool
Numerical Precision
Stainless and niobium
machining
Fermilab, JLab
Furnace and various
expertise
Niobium-to-stainless
braze
ANL Approach to Cavity Fabrication
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162.5 MHz Half-wave Cavity
Exploded View
Niobium Assembly
8+1 total units
Starting point for cavities is EM model together with niobium parting/forming
Stainless jacket
48 inches
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162.5 MHz Half-wave Niobium Sheet Layout
Units are inches, sheets are 0.125 inches thick, RRR>250
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Niobium Parts Forming in US Industry
Upper housing Center conductor Re-entrant nose
Bottom dome Toroid top side Toroid inside
Doubler plate Lower housing Coupling port
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Cavity Port Braze Assemblies
Niobium-to-stainless braze using pure copper
Conflat flange is machined into stainless blanks
Bellows attached (welded) to cavity flange and also helium vessel
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Niobium Wire Cutting in US Industry
Wire EDM Sinker EDM
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Cavity re-entrant nose (beam port nose) assemblies
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Parts received from forming vendor
Doubler OD is trimmed to size with wire EDM Cooling holes added
Doublers are beam welded to re-entrant nose
Beam port braze assembly is welded to nose assembly
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Electron Beam Welding in US Industry
Seam weld Seam weld
Doubler weld Beam port weld
Re-entrant nose weld Housing assembly weld
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Electron Beam Welding in US Industry
Completed niobium assembly
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Electron Beam Welding/Tuning
Major sub-assembly before closure weld
Final niobium assembly
Two circumferential welds and two
longitudinal welds to close cavity
Final closure weld on the HWR’s ‘trickier’ than for QWR’s Weld beads on closure weld cross at 90 degrees Fit tolerance challenging on outer housing Risk (has been) mitigated by testing on weld samples
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Example of tuning steps for QWR
Cavity Tuning by Clamping and Wire EDM
Small rings removed from center conductor and housing
Clamping subcomponents for frequency checking
Final ‘cold’ frequency
Initial frequency before welding subcomponents
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Stainless Steel Helium Jacket Fabrication in US Industry
Backfilling cavity with Argon gas prior to welding
Argon purge in He space for welding
Final TIG weld Final weld joining cavity to stainless (low total heat relative to TIG)
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600 C Hydrogen Degassing is planned
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FNAL High-vacuum furnace
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Half-wave Cavity Testing in ANL 2 K – 4 K Cryostat
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All crygenics connections
– 1.8 K to 4.6 K operation
Diagnostics
– Phase-lock electronics
– Thermometry
– 2nd Sound Detection
– Microphonics measurements
400 Watts RF power at 162.5 Mhz
– Will require a new amplifier for high-power testing
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Timeline for Prototype Fabrication
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16 months timescale to finish testing of a prototype consistent with recent experience with 72 MHz QWR
Prototyping is to establish specific fixturing and manufacturing details to guide production ― Time is not allocated to address fundamental performance issues such
as failure to make gradient due to e.g. bad niobium or problems in EM design
30% schedule float in ID 24 and 50% in ID 26 to account for conflicts with ARRA upgrade
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Summary of Fabrication
Nearly all fabrication techniques are similar or identical for QWR’s and HWR’s and are well understood
Small differences in fabrication techniques will be addressed in the prototyping, e.g., – Crossing weld beads
– ‘Clam shell’ outer housing
– Facilities for processing and testing cavities exist and require modest fixturing for HWR work
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