Business Overview in support of - PowerPoint Presentation

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Business Overview in support of

SRF Cavity Capability

C.F. Roark Welding & Engineering Co., Inc.

LCWS 2018

Arlington, Texas

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Legacy of Family’s Commitment and Heart in Metal Fabrication & Exploration

Complex Metal Fabrication

1923

2014

John L. Roark, Blacksmith

C.F. Roark, Founder, Chairman of the Board

1950

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2018

Ted Roark, President

Jordan Roark, Manufacturing

Engineer, 4

th

Generation

Complex Metal Fabrication

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Organizational Review

BusinessFounded 1949, Family owned for 65 years

Sales: 2017 over $10.6 million 2018 estimated over $11.0 million

70,000 sq. foot facility on 14 acres

Employment level – 85

51 - Operations 12 - Operations Supervision/Mgmt/Programs 14 – Engineers (8 Mfr, 5 Qual, 1 elec)

8 - Admin/Officers

Complex Metal Fabrication

Accreditations

ISO9001:2008, AS9100-B

Welding, NDT, Heat Treating,

Nonconventional Machining and

Chemical

Processing

FAA Repair Station:

YWER845L

Objectives

100% Customer Satisfaction

95% or greater on-time

(Production)

deliveries

Continuing Improvement

Lean initiatives

AS9100/ISO9001

awareness for all

personnel

Scrap – 2% or less

Rework - 3.5% or less

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Customers Include

General Electric Honda Aero Rolls Royce USAF

Raytheon Fermi Labs

MSU – FRIB

General Atomics

Sales Overview

Markets Served

Aerospace

Engine, Gas Turbine

Airframe

Missile

Energy

Gas Turbine

Steam Turbine

Science

Niobium Fabrication

He Vessel Fabrication

Complex Metal Fabrication

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Roark’s SRF

Technology CommitmentStrategic decision to use decades of complex fabrication, machining and EBW expertise to diversify into markets serving the SRF community Technology investments

EBW – Two Large Sciaky EBW Systems

Chemical processing

Frequency Tuning

Leak Detection

FNAL/FRIB development work

FRIB production

“Build

to

print”

supplier to SRF community

Complex Metal Fabrication

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Complex Metal Fabrication

EBW – Two Large Sciaky EBW Systems

Working Area: 138” wide x 108” deep x 107” tall

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Complex Metal Fabrication

Chemical Processing

BCP etching (weld joints only)

Electro Polishing – Exploring Options

Frequency Tuning :

Past ProjectsRF Frequency measurement and machining for FRIB 322 MHz ß=0.29 Half Wave ResonatorRF Frequency measurement and machining for FRIB 322 MHz ß=0.53 Half Wave Resonator

RF Frequency machining for FNAL 162 MHz ß=0.22 Single Spoke

Resonator

Leak

Detection

Helium Mass Spectrometer Leak Detection to a sensitivity of 1 X 10e-10 Std cc He/Sec per ASTM E498/498M

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FNAL Remarks on SRF Quality:

“Making the superconducting radio-frequency cavities is a difficult task because they must be almost flawless.”“Superconducting

cavities are the core, the heartbeat of the International Linear Collider.” 

Quality is delivered in all we do at C.F. Roark

Complex Metal Fabrication

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Complex Metal Fabrication

"While supporting FNAL on a number of HEP (High

Energy

Physics) accelerator projects during the years of 1999– 2008, I had the pleasure to work with the team at C.F. Roark, their strong commitment to the success of our project came through on all

levels."

Giobatta LANFRANCOFeeders Mechanical Engineer

Feeder Assembly Responsible Officer In Cryostat Assembly Section10

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Complex Metal Fabrication

1.3 GHz 9 Cell Tesla RF

Cavity 3.9 GHz Short 1 Cell NB

Cavity

1.3 GHz Short 1 Cell NB Cavity

HINS Front End Single Spoke Resonator

322 MHz B=0.29 Dressed Resonator 322 MHz B=0.53 Dressed Resonator

Past SRF Projects Include:

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Complex Metal Fabrication

Science Customers

Include: FRIB

- Facility for Rare Isotope Beams (MSU)

FNAL - Fermi National Accelerator Laboratory

ANL - Argonne National

Laboratory ORNL - Oak Ridge National Laboratory GA – General Atomics

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“Collaboration seems to run

at a better level…”

Ted

Roark, President

“Our experience with supporting

the science community has always been fascinating. We have found each team to be more open for exploration in the design stages, focusing on manufacturability.

Much different, compared to our general experiences when manufacturing directly with the OEMs in our aerospace business segment.”

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Complex Metal Fabrication

Experienced Shape Forming:

Your results in the lab begins with our shaping your materials

…

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Complex Metal Fabrication

From Concept to CAD model to Completion,

Your ideas come together at C.F. Roark

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Complex Metal Fabrication

FNAL - Resonator Examples

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Complex Metal Fabrication

MSU – FRIB Cavities – Outer Conductors

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Complex Metal Fabrication

MSU – FRIB Cavities

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Complex Metal Fabrication

MSU – FRIB Cavities

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Complex Metal Fabrication

1.3 GHz 9-Cell Cavity

Production

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Complex Metal Fabrication

1.3

GHz 9-Cell Cavity

Production

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Complex Metal Fabrication

“GA

has struggled with finding key fabrication suppliers, and Roark stepped up to initiate a development effort for the EBW.  

The

development results have been successful thus far, and Fermilab has approved moving forward with the pre-production, tooling phase

.”

Amy Bozek, Program Mgr. - Mu2eGENERAL ATOMICSElectromagnetic Systems Group (GA-EMS)

Mu2e Project

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1.3 GHz

9-cell CavityFRIB½ Wave Resonator

SSR1Spoke Resonator

1.3 GHz

9-cell Cavity

Part Gallery – Niobium Fabrication

Complex Metal Fabrication

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Supporting Processes

Complex Metal Fabrication

Vacuum Leak Detection

Ultrasonic Cleaning

Clean Room

Fume Hood

UP Water

Frequency Tuning

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Complex Metal Fabrication

International Linear Collider 

16,000 of these cavities

will be required for

the ILC

SRF-superconducting

radio-frequency cavities25

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Complex Metal Fabrication

Complex Metal Fabrication

You can count on

o

ur Commitment and Heart for Exploration in supporting all of you here today.

The

ILC Project

When you are ready, we will be ready

…

Ted Roark, President

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Complex Metal Fabrication

Our Other side of the

Business

…

Aerospace/Energy

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Complex Metal Fabrication

Mixing Ducts

Centerbodies/

Exhaust Cones

Combustor/Covers

Combustor/Liners

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Our Capabilities Include:

ProcessesMaterials JoiningElectron Beam WeldingTIG Welding

Resistance WeldingThermal Processing (Laser, Heat Treat, Braze)

Turning

Milling/DrillingForming

InspectionCMM, Optical Comparator, Layout

NDT (FPI, X-ray)RF Frequency TuningVacuum Leak DetectionMET lab

Cleaning (Ultrasonic, Alkaline, BCP, etc.)

Tool Design/Fabrication Group

Complex Metal Fabrication

Materials

Nickel/Cobalt based Hi-temp alloys

Titanium

Niobium

Aluminum

Stainless Steel

Systems

ERP (Made2Manage system)

Quality

ISO9001:2008

AS9100-C

Program Management

‘Critical Chain’ methodology

‘Pro Chain’ Project Scheduling

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Complex Metal Fabrication

Electron Beam Welding

Sciaky CNC-controlled

EB welding

facility

(Diffusion Pumps utilize non-silicon based oil)

Qty

Description

1

Sciaky EB - 250 MA, 60 KV

VX.112 x 50 x 62

1

Sciaky EB - 500 MA, 60 KV

VX.68 x 68 x 78

2

Sciaky EB - 700 MA, 60 KV CNC

VX.138 x 107 x 108

TIG Welding

Manual & Automatic

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Resistance Welding

Complex Metal Fabrication

Qty

Desc

Specs

6

Sciaky

Spot Welders

60-400KVA

4

Sciaky

Seam Welders

125-250KVA

1

Federal Tweezer Welder

1

Projection Welder

100KVA

Laser

(1) Trumpf

TLC Cut 5

CO2 (2.7 KW)

5 axis 10’ x 4’ x 2’

(1) Westinghouse/ILM

YAG (400 watt)

5 axis 10’ x 4’ x 3’

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Heat Treating - Vacuum

Horizontal - 66 DIA X 96LComplex Metal Fabrication

Precision Quincy 5E-50X50

72” cubic workspace

Vertical Bottom Load - 60 DIA X 60 Tall

Heat Treating - Air

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CNC Machining: VTL Turning

Complex Metal Fabrication

CNC Turning

Combined Turning

to

74” dia.

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Horizontal & Vertical Machining Centers

Complex Metal Fabrication

5-Axis Machining

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Forming

Complex Metal Fabrication

Type

Qty

Description

Brake Press

1

175 Ton

Cincinnati

10 foot width

Punch Press

3

90 Ton Horn

3

125 Ton OBI

1

175 Ton Gap

Hydraulic Press

3

100 Ton Hannifin

1

500 Ton Triple Action HPM

5

Expanders

Various Sizes

1

175 Ton Cincinnati

OBS

1

75 Ton Cincinnati

OBS

Rolls - Plate/Sheet

2

Up to 3/8” capacity

4 foot width

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Complex Metal Fabrication

Quality

Lean Initiative

Quality & Delivery Clinic

Layout

NDT

X-ray/FPI

CMM - Work Zone 34”x49”x94”

Metrics Evaluation

Calibration

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Contact InformationComplex Metal Fabrication

Position

Name

Email

address

PresidentCharles (Ted) Roark

troark@roarkfab.com

COO / CFO

Rick Bell

rbell@roarkfab.com

Contract

Administration

Bill Golay

bgolay@roarkfab.com

Quality Manager

Tobie Brown

tbrown@roarkfab.com

Engineering - Fabrications

Ty Phelps

tphelps@roarkfab.com

Engineering - NPI

Brad Beeson

bbeeson@roarkfab.com

Engineering

– EBW/ScienceDwight Oshadosha@roarkfab.com

Operations - ManagerBryson Ockerbocker@roarkfab.com

Operations - EBW

Jim Daffinee

jdaffinee@roarkfab.com

Business Development

Paul Gearing

paul@gearing.biz

136 N Green St. Brownsburg, IN 46112

Phone: 317-852-3163 Fax

317:852-2738

www.roarkfab.com

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All

Acronymshttps://www.allacronyms.com

Slide39

What does LCWS

 mean?Top 12 meanings of LCW acronym or abbreviation:

Low-Cost WorkstationLow Continuous Wall SuctionLutheran College Washington Semester

Lake Champlain Waldorf School Lake County Wine

Studio Los Cerritos Wetlands StewardLancashire Computer Waste ServicesLive Chain WorkFlow Studio

Little Campbell Watershed SocietyLois and Clark Withdrawal Syndrome Library of Congress Web Server

Low Cost Weapon Delivery SystemAll Acronymshttps://www.allacronyms.com