joint r&d projects with industry · - industrial production of full nine-cell cavities: -...

Joint R&D Projects with IndustryCarlo Pagani

University of MilanoINFN Milano-LASA & GDE

Erice FEL Workshop 25-26 October 2006

Carlo Pagani 2

Energy Frontier and Accelerator Tech.

ILC

Superconducting Magnets

Superconducting RF Cavities

LHC Dipole String

LEPII Cavity String


Carlo Pagani 3

From Basic Research to Industry

High Energy Physics is pushing the limits of Acc. Technology– Goals beyond the actual technology limits– Large, internationally supported, projects– Strong participation from Industry– Strict Requirements on Quality Assurance and Quality Control

Other science fields are applying results and making progress– Synchrotron Light Sources– Humane Science: Medicine and Biology– Spallation Neutron Sources– Free Electron Lasers– Future energy plants: Fusion and Nuclear Waste Transmutation

Industry took benefit from supported R&D– Industrial and medical applications of SLAC type linacs– Medical applications of Superconducting Magnets– and many other examples


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K800 Superconducting Cyclotron: CS

3 Italian Industries involvedAnsaldo: Superconducting MagnetZANON: RF Cavities & CryostatEM-LMI: Superconducting cables


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HERA SC Magnets

SC dipoles shared between German and Italian Industry

Proton Ring SC Dipoles (~ 500) Large SC Solenoid in ZEUS

SC solenoid from Italy


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European Effort for LHC Dipoles1250, 15 m, Dipoles delivered by European Industry

~ 1200 cold tested~ 600 installed into the tunnel


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Large SC Coils from JET to ITER

16 MW power produced, 1s 500 MW, 400s


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At Michigan General Hospital

230 MeV Proton Cyclotron

Treatement hall

The Gantry

Designed and Developed by research institute with Industry

Produced and commercialized by Industry (ACCEL)


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SC magnets: Maglev Trains

Maglev: Magnetic levitation train

Shanghai commercial TransrapidGerman experimental Transrapid


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Superconducting RF before TESLA“Livingston Plot” from Hasan Padamsee


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Large Project Impact on SRF

The decision of applying this unusual technology in the largest HEP and NP accelerators forced the labs to invest in Research & Development, infrastructures and quality controlThe experience of industry in high quality productions has been taken as a guideline by the committed labs At that time TJNAF and CERN played the major role in SRF development, mainly because of the project sizeThe need of building hundreds of cavities pushed the labs to transfer to Industry a large part of the productionThe large installations driven by HEP and NP produced a jump in the fieldR&D and basic research on SRF had also a jump thanks to the work of many groups distributed worldwide

LEP

CEBAF


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CEBAF and LEP II

LEP II & CERN

32 bulk niobium cavitiesLimited to 5 MV/mPoor material and inclusions

256 sputtered cavitiesMagnetron-sputtering of Nb on CuCompletely done by industryField improved with time<Eacc> = 7.8 MV/m (Cryo-limited)

352 MHz, Lact=1.7 m

1.5 GHz, Lact=0.5 m5-cell cavities

4-cell cavities

CEBAF

338 bulk niobium cavitiesProduced by industryProcessed at TJNAF in adedicated infrastructure


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Important technological steps

Use of the best niobium (and copper) allowable in the market at the time Industrial fabrication of cavity components with high level quality controlAssembly of cavity components by Industry via Electron Beam welding in clean vacuum Use of ultra pure water for all intermediate cleaning Use of close loop chemistry with all parameters specified and controlledCavity completion in Class 100 Clean Room

– Final cleaning and drying (UV for bacteria and on line resistivity control)

– Integration of cavity ancillaries

That is

New level on Quality Control


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LEP II Cavities in Industry (Ansaldo)


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Origin of the Linear Collider Idea

A Possible Apparatus for Electron-Clashing Experiments (*).

M. TignerLaboratory of Nuclear Studies. Cornell University - Ithaca, N.Y.

M. Tigner, Nuovo Cimento 37 (1965) 1228

“While the storage ring concept for providing clashing-beam experiments (1) is very elegant in concept it seems worth-while at the present juncture to investigate other methods which, while less elegant and superficially more complex may prove more tractable.”


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Linear Collider conceptual scheme

Electron GunDeliver stable beam current

Damping RingReduce transverse phase space (emittance) so smaller transverse IP size achievable

Bunch CompressorReduce σz to eliminate hourglass effect at IP

Positron TargetUse electrons to pair-produce positrons

Main LinacAccelerate beam to IP energy without spoiling DR emittance

Final FocusDemagnify and collide beams


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Fighting for Luminosity

yx

e

c.m.

b

σσN

EPL ×∝

Parameters to play withReduce beam emittance (εx

.εy ) for smaller beam size (σx.σy )

Increase bunch population (Ne )Increase beam powerIncrease beam to-plug power efficiency for cost

nb = # of bunches per pulse

frep = pulse repetition rate

Pb = beam power

Ec.m.= center of mass energy

L = Luminosity

Ne = # of electron per bunch

σx,y = beam sizes at IP

IP = interaction point

( )repbb fnNP ××∝ e

yx

2e

σσNL ∝ xσ

yσrepb fnL ×∝


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A Simple Exercise

Synchrotron Radiation (SR) becomes prohibitive for electrons in a circular machine above LEP energies:

RF system must replace this loss, and r scale as E2

LEP @ 100 GeV/beam: 27 km around, 2 GeV/turn lostPossible scale to 250 GeV/beam i.e. Ecm = 500 GeV:– 170 km around– 13 GeV/turn lost

Consider also the luminosity– For a luminosity of ~ 1034/cm2/second, scaling from b-factories gives

~ 1 Ampere of beam current– 13 GeV/turn x 2 amperes = 26 GW RF power– Because of conversion efficiency, this collider would consume more

power than the state of California in summer: ~ 45 GW

Both size and power seem excessive

[ ] [ ]kmr1106GeV 421 ⋅γ⋅⋅= −

SRUUSR = energy loss per turnγ = relativistic factorr = machine radius

γ250GeV = 4.9 . 105

Circulating beam power = 500 GW


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Competing technologies for the ILC

30 GHz-Warm

11.4 GHz - Warm

1.3 GHz - Cold

Evolution from: CEBAF & LEPII+ TRISTAN, HERA, etc.

Evolution from: SLAC & SLC+ hundreds for research & application


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LC status at second ILC-TRC

3

4

195

6.9

20

11.4

JLC-X/NLC VLEPP

1.245σy* [nm]

143γεy [×10-

8m]

175233140PAC [MW]

4.95.811.3Pbeam [MW]

211434L×1033 [cm-2s-

1]

30.05.71.3f [GHz]

CLICJLC-C

JLC-SSBLCTESL

A

January 2003 Ecm= 500 GeV


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Beam Sizes

© M. Tigner


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LC Organisation up to August 2004


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From the ILC Birthday


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From the ILC Birthday


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ILC Pictorial View (TESLA Like)

As at the Technology Recommendation time


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From the Day After

Robert Aymar (CERN): “A linear collider is the logical next step to complement the discoveries that will be made at the LHC. The technology choice is an important step in the path towards an efficient development of the international TeV linear collider design, in which CERN will participate.”Yoji Totsuka (KEK): “This decision is a significant step to bring the linear collider project forward. The Japanese high-energy community welcomes the decision and looks forward to participating in the truly global project.”Jonathan Dorfan (SLAC): “Scientific discovery is the goal. Getting to the physics is the priority. The panel was presented with two viable technologies. We at SLAC embrace the decision and look forward to working with our international partners.”

Similar Declarations from: Albrecht Wagner (DESY), Hesheng Chen (HEP), Michael Witherell (FNAL) et al.

From the ICFA press release, Beijing, 20 August 2005


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Start of the Global Design Initiative

~ 220 participants from 3 regionsmost of them accelerator experts


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Global Design Effort (GDE)

On March 18, 2005, during the opening of LCWS05 workshop at Stanford University, Barry Barish officially accepted the position of Director of the Global Design Effort, GDE (yet to be formed)


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GDE Actual Members

49 67


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LCH and ILC Module Comparison

From an LHC Status Report by Lyndon R. Evans

ACC 4 & ACC 5 in TTF ACC 2 & ACC 3 in TTF

∅ = 38”

∅ = 38” ∅ = 42”


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The TESLA Collaboration Mission

Develop SRF for the future TeV Linear ColliderBasic goals

• Increase gradient by a factor of 5 (Physical limit for Nb at ~ 50 MV/m)• Reduce cost per MV by a factor 20 (New cryomodule concept and Industrialization)• Make possible pulsed operation (Combine SRF and mechanical engineering)

Major advantages vs NC Technology• Higher conversion efficiency: more beam power for less plug power consumption• Lower RF frequency: relaxed tolerances and smaller emittance dilution

as in 1992

Björn Wiik


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TESLA Coll. Milestones before 08/2004

February 1992 – 1° TESLA Collaboration Board Meeting @ DESY

March 1993 - “A Proposal to Construct and Test Prototype Superconducting RF Structures for Linear Colliders”

1995 – 25 MV/m in multi-cell cavity

May 1996 – First beam at TTF

March 2001 – First SASE-FEL Saturation at TTF

March 2001 – TESLA Technical Design Report

February 2003 –TESLA X-FEL proposed as an European Facility,50% funding from Germany

2004 – TTF II Commissioning start

April 2004 - 35 MV/m with beam

Infrastructure @ DESY in Hall 3

TESLA X-Ray FEL

TESLA Collider

TTF II

TTF I


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TESLA cavity design and rules

Hz/(MV/m)2≈ -1KLorentz

kHz/mm315Δf/Δl

mT/(MV/m)4.26Bpeak/Eacc

2.0Epeak/Eacc

Ω1036R/Q

TESLA cavity parameters

- Niobium sheets (RRR=300) are scanned by eddy-currents to detect avoid foreign

material inclusions like tantalum and iron

- Industrial production of full nine-cell cavities:

- Deep-drawing of subunits (half-cells, etc. ) from niobium sheets

- Chemical preparation for welding, cleanroom preparation

- Electron-beam welding according to detailed specification

- 800 °C high temperature heat treatment to stress anneal the Nb

and to remove hydrogen from the Nb

- 1400 °C high temperature heat treatment with titanium getter layer

to increase the thermal conductivity (RRR=500)

- Cleanroom handling:

- Chemical etching to remove damage layer and titanium getter layer

- High pressure water rinsing as final treatment to avoid particlecontamination

Figure: Eddy-current scanning system for niobium sheets Figure: Cleanroom handling of niobium cavities

9-cell, 1.3 GHz

Major contributions from: CERN, Cornell, DESY, CEA-Saclay, INFN


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TTF: a new infrastructure at DESY

TTF I as operated for SASE FEL


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Chemistry, HPR and String Assembly


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Learning curve with BCP

3 cavity productions from 4 European industries: Accel, Cerca, Dornier, Zanon4th production of 30 cavities concluded, also to define Quality Control for Industrialization

BCP = Buffered Chemical Polishing

Module performance in the TTF LINAC

Improved weldingNiobium quality control

<Eacc> @ Q0 ≥ 1010 <Eacc> @ Q0 ≥ 1010

<1997>

<1999>

<2001>


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3rd cavity production with BCP

1E+09

1E+10

1E+11

0 10 20 30 40Eacc [MV/m]

Q0

AC55 AC56AC57 AC58AC59 AC60AC61 AC62AC63 AC64AC65 AC66AC67 AC68AC69 AC79

1011

109

1010

3rd Production - BCP CavitiesStill some field emission at high fieldQ-drop above 20 MV/m not cured yetJust AC67 discarded (cold He leak)

TESLA original goal

Vertical CW tests of naked cavitis

Q-drop


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EP & Baking for 35 MV/m

Electro-Polishing (EP)instead of

Buffered Chemical Polishing (BCP)• less local field enhancement• High Pressure Rinsing more effective• Field Emission onset at higher field

In Situ Baking@ 120-140 ° C for 24-48 hours

• to re-distribute oxygen at the surface

• cures Q drop at high field

EP at the DESY plant• Low Field Emission 800°C annealing

120°C, 24 h, Baking• high field Q drop curedHigh Pressure Water Rinsing

Vertical and System Test in 1/8th CryomoduleThe AC 70 example


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Cavity Production: EB welding and QC


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New QC tools in 4th Production

© V. Singer


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Performing Cryomodules

Required plug power for static losses < 5 kW/(12 m module)

Reliable Alignment Strategy

Sliding Fixtures @ 2 K

“Finger Welded” Shields

Three cryomodule generations developed by INFN in collaboration with Industry to:

improve simplicity and performances minimize costs


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The module assembly is a well defined and standard procedure.

• experience of 10 modules exists

• the latest generation (type III) will be used for series production (XFEL requires 120 modules)

• several cryogenic cycles as well as longtime operation were studied

• the assembly problems occurred are well understood and cured

Module Assembly


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Cryoodules installed in TTF II

RF gun

400 MeV 120 MeV800 MeV

ACC 1ACC 2ACC 3ACC 4ACC 5

4 MeV

ACC 4 & ACC 5 ACC 2 & ACC 3


Carlo Pagani 44

TTF Module # 4 Installed


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Towards ILC Cryomodule

International collaborative Effort in the three regions for Type IVDesign changes are mainly those anticipated on the TESLA TDR– Costing based on TTF/TESLA

experience (and XFEL)


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High Power RF System

Thales TH1801 CPI VKL8301 Toshiba E3736


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3D Model of a dressed cavity


Carlo Pagani 48

Coupler Development at LAL-Orsay

TTF III

Clean room assemblyHigh Power Coupler Test Stand

Alternative Designs


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Ancillaries: Cavity Tuners

The Saclay Tuner in TTF The INFN Blade-Tuner

Successfully operated with superstructures


Carlo Pagani 50Status as on February 1st, 2005

The Blade-Tuner for ILC

• Integration of piezos for Lorentz forces and microphonics completed.

• Two prototype, including the modified helium tank, are being build for cold qualification

• Tests at Fermilab, DESY and BESSY


Carlo Pagani 51

Low Level RF Control

mechanical tuner (frequency adj.)

DAC

DAC

ADC

ADC

LowLevelRF

System

vector sum

vector demodulator

pickup signal

MBK Klystron

vector modulator

cavity #1 cavity #8

coaxial coupler

circulator

stub tuner (phase & Qext)

accelerator module 1 of 4


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RF Gun LLRF with SIMCON 3

Amplitude and phase regulation by calculating the vector sum of forward and reflected powerFPGA based controller in operation since Dec 2005Phase stability of 0.14 deg at1.3 GHz or 300 fs achieved


Carlo Pagani 53

TTF: First 7 year balance (1992-98)

Funding

Major Contributing Countries(including personel)

Germany (DESY + ) ~ 50%

France (CEA + IN2P3) 10-15%

Italy (INFN) 10-15%

USA (Fermilab + ) 10-15%

Design

Major Contributing Institutes(in alphabetic order)

CEA/IN2P3

CERN

DESY

INFN

Fermilab & Cornell for USA

> 100 Million DM Invested on the TESLA SRF Technology


Carlo Pagani 54

Global SCRF Test Facilities for ILC

TESLA Test Facility (TTF II) @ DESYTTF II is currently unique in the worldVUV-FEL user facility (now called FLASH)test-bed for both XFEL & ILCCryomodule Test Stand under commissioning

SMTF @ FNALCornell, JLab, ANL, FNAL, LBNL, LANL, MIT,MSU, SNS, UPenn, NIU, BNL, SLAC in US+ DESY, INFN & KEK in the other 2 Regions

STF @ KEKaggressive schedule to produce high-gradient(45MV/m) cavities / cryomodules

EU SCRF Infrastructure at CERN ?under discussion for FP7


Carlo Pagani 55

STF @ KEK


Carlo Pagani 56

SMTF @ FNAL as presented to DOE

“The SMTF proposal is to develop U.S. Capabilities in high gradient and highQ superconducting accelerating structures

in support of

International Linear ColliderProton Driver

RIA4th Generation Light Sources

Electron coolerslepton-heavy ion colliderand other accelerator

projects of interest to U.S and the world physics

community.”


Carlo Pagani 57

Great Impulse from TESLA Results

High Energy Physics: Leptons and Hadrons– ILC is growing cold– 8 GeV Proton Driver for FNAL– SPL for CERN: neutrinos and LHC upgrade– Electron coolers– ……

Nuclear Physics: Ions and Electrons– Spiral 2– RIA – Eurisol– Spes– CEBAF Upgrade– ……

Applied Physics: Electrons– Spallation Neutron Sources: SNS– 4th Generation Light Sources: European X-FEL– Storage Rings– Energy Recovery Linacs: 4GLS in Europe and many

others– ……

ADS for Nuclear Waste Transmutation– EuroTrans 600 MeV

ILC

SNS @ ORNL


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Cavity Fabrication Industrial StudiesProduction Plan for 20,000 cavities


Carlo Pagani 59

Industries at the ITRP visit @ DESY


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One Industrial Forum in Each Region

Both Operational


Carlo Pagani 61

European Industrial Forum for SCRF

https://indico.desy.de/conferenceTimeTable.py?confId=61

http

s://

trac

.lal.in2

p3.f

r/SC

RF


Carlo Pagani 62

ILC Site power: 140 MW ~ 200MWTESLA 500 GeV ILC

Sub-Systems 43MW

Main Linacs97MW

Cryogenics:

21MW

RF: 76MW

65%

78%

60%

Beam 22.6MW

Injectors

Damping rings

Auxiliaries

BDS


Carlo Pagani 63

SRF Technology Beyond ILC

Most of the new accelerator based projects, in construction or just proposed, are widely using Superconducting RF technology.

The worldwide coordinated effort behind the TESLA project has been driving a new level of understanding of the past limiting factors.

At present industry is producing turn-key reliable systems that include SRF cavities and cryo-ancillaries.

The European X-FEL will represent the first large scale application based on the TESLA Technology. Its realization will be naturally synergic with the Linear Collider

ILC effort is expected to move SRF technology to the level required for its wide application beyond fundamental physics


Carlo Pagani 64

European XFEL Layout and Site

joint r&d projects with industry · - industrial production of full nine-cell cavities: -...

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