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5 th  CLIC-ACE  Structure production in laboratories and in industry 5 th  CLIC-ACE  Structure production in laboratories and in industry

5 th CLIC-ACE Structure production in laboratories and in industry - PowerPoint Presentation

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5 th CLIC-ACE Structure production in laboratories and in industry - PPT Presentation

G Riddone 02022010 1 Content Introduction to RF structures and components Fabrication baseline procedure for accelerating structures Application to CERN ac structure fabrication Fabrication of PETS ID: 781232

5th clic ace riddone clic 5th riddone ace 2010 structures cern slac assembly pets vacuum fabrication structure procedure accelerating

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Slide1

5th CLIC-ACE Structure production in laboratories and in industry

G. Riddone, 02/02/2010

1

Slide2

ContentIntroduction to RF structures and components

Fabrication baseline procedure for accelerating structures Application to CERN ac. structure fabrication

Fabrication of PETS

Production capability

Master schedulePresent structures (CERN, KEK, SLAC, Elettra, PSI)Towards CLIC structures (CDR, TDR)

G. Riddone, 5th CLIC-ACE, 02/02/2010

2

Slide3

Introduction G. Riddone, 5th CLIC-ACE, 02/02/2010

3

TD18#3 at SLAC

TD18#2 at KEK

TD24#2 at CERN (12 GHz)

PETS (12 GHz, TBTS)

PETS (11.4 GHz, test at SLAC)

High-power dry load

Hybrid

Variable

high power splitter

Slide4

Fabrication of accelerating structuresG. Riddone, 5th CLIC-ACE, 02/02/2010

4

Three T18 structures tested at SLAC/KEK

showed excellent test results

consequent validation of

design, machining and assembly procedure

NLC/JLC fabrication technology: validated to

100 MV/m (baseline for future CERN X-band accelerating structures)

Slide5

Baseline procedureG. Riddone, 5th CLIC-ACE, 02/02/2010

5

Diamond machining (sealed structures)

H2 diffusion bonding/brazing at ~ 1000 ˚C

Cleaning with light etch

Vacuum baking

650 ˚C > 10 days

J.

Wuang

J.

Wuang

Slide6

Application to CERN accelerating structuresCERN previous assembly procedure was based on vacuum brazing at 800 ˚C  several changes were needed to get towards the baseline procedure

Following the post-mortem analysis of the two CERN accelerating structures T18 and T24, contamination (C, Ca) resulted to be the main problem 

cleanliness had to be seriously improved

G. Riddone, 5th CLIC-ACE, 02/02/2010

6

Slide7

Application to CERN accelerating structures - procedure

High precision diamond machining

Cleaning

(light etch)

Brazing of coupler bodies, cooling circuits, tuning studs

(

AuCu

, 1020 °C)

Packaging and shipping

Brazing of couplers

(H

2

, 1045 °C,

AuCu

)

Machining of couplers

Diffusion bonding of disk stack

(H

2

, 1020 °C)

RF check and tuning

Baking

(vacuum,

650 °C, >10 d)

QC

G. Riddone, 5th CLIC-ACE, 02/02/2010

7

Slide8

Inspections G. Riddone, 5th CLIC-ACE, 02/02/2010

8

Microscopic inspection of disks before and after cleaning (on

witness pieces

)

Video inspections, SEM and microscopic inspections

Microscopic inspections before and after each relevant fabrication step

T18 KEK/SLAC design

Slide9

Manufacturing at VDL

All dimensional checks are conform

Shape tolerance

±2.5

m

m

Damped disk at 12 GHz

9

G. Riddone, 5th CLIC-ACE, 02/02/2010

New

CMM (

Coordinate Measuring

Machine)

under procurement

at CERN

Slide10

Cleaning G. Riddone, 5th CLIC-ACE, 02/02/2010

10

SLAC cleaning procedure as a baseline

For

degreasing

Trichloroethane

 

at SLAC

replaced by

Perchloroethylene

CERN procedure:

(Firm AVANTEC Performance Chemicals):

- TOPKLEAN MC 20A

- PROMOSOLV 71IPA

Tool for holding the disks

Etching

J.

Wuang

Slide11

Diffusion bonding

G. Riddone, 5th CLIC-ACE, 02/02/2010

11

1045 °C, 2 h

couplers

Couplers + disks

1020 °C, 1.5 h

TD24

TD24

T18KS

Disks

Bonding at CERN: few mbar H2 partial pressure (difference with SLAC): we are actively looking for a furnace at 1 bar H

2

in Europe.

Slide12

AssemblyG. Riddone, 5th CLIC-ACE, 02/02/2010

12

Assembly made on V-blocks

Verification of the assembly (before and after bonding) with a new measurement column: straightness and tilt

Straightness measurement

±2

m

m

Slide13

Accelerating structure TD24 after diffusion bonding under H2

Large grain size!

13

G. Riddone, 5th CLIC-ACE, 02/02/2010

Slide14

Vacuum bakingG. Riddone, 5th CLIC-ACE, 02/02/2010

14

J.

Wuang

1

st

baking: TD24 for CLEX,

two-beam test stand

CERN furnace

 s

everal mechanical adaptations were needed

10

-9

mbar

Slide15

RF check and tuningG. Riddone, 5th CLIC-ACE, 02/02/2010

15

Bead pulling at

11.421GHz (old test-set-up)

Before shipping RF check and tuning

were done

and results

were

good

T24#1

New test set-up is under procurement for RF measurements

Slide16

Clean roomG. Riddone, 5th CLIC-ACE, 02/02/2010

16

Clean room layout

Boxes under N2

Clean pieces

After the failure of CERN ac. structures, it was clear that a clean room was indispensable

Sealed bag under N2

VESTIBULE

Slide17

Fabrication of PETS at 11.4 GHz

with damping material

G. Riddone, 5th CLIC-ACE, 02/02/2010

17

Bar length ~ 300 mm

Shape tolerance within specification:

± 7.5

m

m

PETS for feasibility

demonstration

under assembly

to be tested at SLAC

Damping material

Coupler

Minitank

with bars inside

Slide18

Fabrication flow for PETS (11,4 GHz)

G. Riddone, 5th CLIC-ACE, 02/02/2010

18

Procedure as close as possible to the baseline, but some difference due to design and infrastructures

Cleaning

(NGL+solvent)

EB welding of the bars

QC

PETS bars

Baking

(vacuum,

200 C, 2 h)

Assembly of the

8 bars

Vacuum test

EB welding of the bars

Packaging (N2)

RF check

Shipping to SLAC

Assembly of couplers-bars and mini-tank

EB welding of tank

Final bake-out (150 C, 2h)

RF check

FINAL ASSEMBLY

Slide19

Fabrication of TBL PETSG. Riddone, 5th CLIC-ACE, 02/02/2010

19

Prototype made by CIEMAT using conventional UHV best practice for cleaning and

handling

Coupler is brazed, no heat treatment for PETS itself

The CERN production will be assembled in a clean

room,

The coupler will be vacuum brazed at CERN

Status: parts fabrication, assembly should start in April

S. Doebert

Slide20

Production capabilityG. Riddone, 5th CLIC-ACE, 02/02/2010

20

3

laboratories:

- ac. structures

SLAC, KEK and CERN

- PETS

 CERN

5 qualified vendors for ac. structures: 2 (CERN), 2 (KEK), 1 (SLAC)

3 qualified vendors for PETS

For each structure, at least two units are manufactured

For KEK, SLAC made structure, the assembly/baking is made at SLAC

- e.g. baking of two structures in parallel

At present, potential capability up to 20. structures per year

Slide21

Present structures: CERN, KEK, SLAC (base and fundamental program)G. Riddone, 5th CLIC-ACE, 02/02/2010

21

CD10

TD24

Slide22

Present structures: CERN(base program)G. Riddone, 5th CLIC-ACE, 02/02/2010

22

1 ac. structure (

CLEX, TBTS)

2 ac. structures with

wakefield

monitors

(

CLEX, TBTS)

Slide23

Other structures

G. Riddone, 5th CLIC-ACE, 02/02/2010

23

Important involvement of other laboratories to exchange experience and to increase the market

900-mm

long structures for PSI (X-FEL) and

Elettra

(

Sincrotone

Trieste) with

wakefield

monitors

72 cells

Wakefield monitor design

Structure assembly

Slide24

Master scheduleG. Riddone, 5th CLIC-ACE, 02/02/2010

24

Slide25

Comparison to Jan 2009 schedule For production overall delay of about 4 months, although not on critical pathCERN structures: break of few weeks before decision to adopt baseline procedure

Several steps of baseline procedure were new for CERN: process qualification needed before application to a real structureBaseline procedure takes longer than the previous based on vacuum brazing at 800 °C

Qualification of new vendors: several trials before

achieving disks within specification

G. Riddone, 5th CLIC-ACE, 02/02/2010

25

Slide26

Towards CLIC structures CDRAccelerating structure with all features: damping material and technical systems: under eng. design (first structure at the end of 2010). Assembly test with a prototype structure are scheduled in the coming weeks.

PETS with on-off system: under design. On-off system to be tested in Q3, 2010Cost estimate in needed by 2010: launched dedicated studies with three companies/institutes

G. Riddone, 5th CLIC-ACE, 02/02/2010

26

Wakefield monitor

Damping material

Coupler

On-off system

AS

PETS

Slide27

T4

T1

T0

Towards CLIC structures

From CDR to TDR

Main linac prototype modules

(

3 by end

of 2012

) will be built to validate the technical systems in an integrated approach

.

G. Riddone, 5th CLIC-ACE, 02/02/2010

27

These modules will contain

accelerating

structures and PETS with all required

features

Industrialization

and mass production development in collaboration with companies

Slide28

ConclusionsG. Riddone, 5th CLIC-ACE, 02/02/201028

NLC/JLC fabrication technology validated for CLIC accelerating structures to 100 MV/m

CERN is implementing NLC/JLC procedures (still in learning process

)

Cleaning (etching)Diffusion bonding at ~1040 °C (H2)Vacuum baking Production capability up to 20 structures per year

 higher than available testing slotsInvolvement of other laboratories to exchange experience and expertise CLIC structures with all features under design: first unit ready by end of this year

Main

linac

prototype modules for CLEX will include CLIC several structures

Industrialization, mass production and cost study launched for few

structure

configurations

Slide29

SPAREG. Riddone, 5th CLIC-ACE, 02/02/2010

29

Slide30

G. Riddone, 5th CLIC-ACE, 02/02/201030

Assembly of accelerating structures

T24

T18 and before

Slide31

Comparison SLAC/CERN31

G. Riddone, 5th CLIC-ACE, 02/02/2010

Slide32

Summary of comparisonG. Riddone, 5th CLIC-ACE, 02/02/2010

32

SLAC/KEK

Fermilab

CERN old

CERN new (SLAC/KEK

based)

Diamond machining

Etch

1000 ˚C pre-fire

(

Ar

)

~ 100

0

˚C diffusion bonding

~

1000 ˚C brazing

~ 800 ˚C brazing

(

Ar

, Au/Cu)

(Vacuum, Ag/Cu)

Vacuum baking

Tank/sealed

SEALED

SEALED

SEALED

TANK

/SEALED

Slide33

QUADRANTS - HDS

thick qualification part according to CLIAAS300062 - KERN

(DE)

Achieved shape accuracy ± 2.1 µm

Roughness Ra = 86 nm – 30 nm according to ISO 97

Achieved shape accuracy ± 1.3 µm

S. Atieh

G. Riddone, 5th CLIC-ACE, 02/02/2010

33

Slide34

Origins translation: X 16 µm and Z -8 µm

Shape accuracy is respected ± 2.5 µm

QUADRANTS - HDS

thick qualification part according to

CLIAAS300062 –

DMP (SP)

G. Riddone, 5th CLIC-ACE, 02/02/2010

34

S. Atieh

Slide35

35

35

T18 CERN - Inspection

on iris 12

Contamination between brazing and testing

35

GR, BE/RF, 19.06.2009

C

C

Ca