Analytical Cost Model (16 T dipole) T. Martínez, J. Munilla, F. Toral - CIEMAT Status of the project- February 2017
Preliminary main cost drivers Manufacturing of main components (strict fabrication tolerances): End spacers Cu-Alloy wedges Iron yoke laminations Iron pads laminations Master keys Conductor and wedges insulation Impregnation Ground insulation Plasma coating insulation Aluminum shell Axial rods End plates Quench Heaters 2
Status of the analytical study End Spacers: Raw material: 316L Production process: 3D printing Reference price (11T): 1.100€ (end saddle)+4.200€=5.300€ per coil Estimation for 16T : Inner layers: 5.300× 50 60 =4.417€ Outer layers: 5.300× 103,8 60 =9.169€ 2 coils and 2 apertures: 54.344€ per magnet High price: another alternative must be considered Scaling by volume 3
Status of the analytical study End Spacers: Suggestion from CERN main workshop: Consider another material for fast machining No excessive grain growth during heat treatment Non magnet Fulfil mechanical/structural specifications Stefano Sgobba will be contacted for recommendations Couple of tons of test melt will be requested to a steel company (to be discussed/budget??) 4
Status of the analytical study Cu-Alloy Wedges: Raw material: CEP DISCUP C3/30 Production process: extrusion Initial assumption: consider just 2 different wedge profiles instead of the real 10 different ones One dipole cold mass contains approximately 560 meters of copper wedges of each different profile. The wedges shall be delivered in 3500 mm long pieces. Consequently in one cold mass there are 160 copper wedges pieces of each profile (considering initial assumption). 5
Status of the analytical study Cu-Alloy Wedges: Quotation for these 2 wedges profiles has been asked to Luvata and Buntmetall: Wedge 10 Wedge 6 Wedge 10 Wedge 6 6
Status of the analytical study Cu-Alloy Wedges: Luvata proposal: Half length: 1750 mm long pieces Manufacturing tolerances change (+/-20 µm fabrication tolerances requested) thickness +/- 0,03 mm width +0,04 /-0,06 mm First cost estimation: Tooling: 1.500€ per profile Material: 90-180€/kg (not confirmed) Budget: 520kg x 90 €/kg= 46.800 € per magnet COST DRIVER!! Note: due to the very different geometries of the profiles a more accurate estimation will come up from the evaluation of the 10 different profiles 7
Status of the analytical study Cu-Alloy Wedges: Our estimation basis on second Luvata’s figures: 520 kg of material per magnet Cost estimation (considering 10 different profiles): Tooling: 1.500 x 10= 15.000€ per 10 wedge profiles (life cycle of tooling?/price of maintenance?) COST DRIVER Mat. Area mm2 quantity 1 dipole mass pcs length mm quantity 1 dipole mass meter kg/m quantity 1 dipole mass kg Luvata's quotation Price EUR/Kg Price EUR Wedge 6 62,32 64 1.750 112 0,56 63 130 8130,12 Wedge 10 20 0,18 250 5017,60 Wedge 1 43,77 0,39 44 140 6149,37 Wedge 2 39,55 0,35 40 180 7144,06 Wedge 3 47,62 0,43 48 6690,27 Wedge 4 49,54 0,44 50 150 7457,16 Wedge 5 41,95 0,38 42 6314,65 Wedge 7 78,27 0,70 79 120 9425,46 Wedge 8 51,24 0,46 51 6684,65 Wedge 9 83,97 0,75 84 10111,87 518,23 mm2 520 73125 €/magnet 8
Status of the analytical study Cu-Alloy Wedges: On December 15th:Meeting at CIEMAT facilities with Ilppo Hiekkanen from Luvata Luvata did not realize the real scale of the project No commercial capacity for getting that amount of raw material Assure lower prices for a very long series Luvata proposses a meeting among the parts: CEP (raw material supplier), LUVATA, CERN and CIEMAT (comment with Daniel …too early for this kind of meeting) Material properties: The minimum specification for the moment is that the tensile strength Rp0.2 should be larger 200 MPa after heat treatment to 650C. Good mechanical properties and a large RRR are an advantage. 9
Status of the analytical study Cu-Alloy Wedges: Buntmetall response: Equipment of hydrostatic pressure does not allow them to use CEP DISCUP C3/30 (CEP DISCP-powder metallurgical process and Buntmetal alloys- melting&casting ) Another alternative under development: Our requirement: Yield strength of 200MPa after a heat treatment at 650°C Information requested by the company: dwell time at 650°C: 10 hours? the required electrical conductivity? (to be discussed) Buntmetal starts a direct collaboration with Daniel (They want to do the development of the wedges and they will send him an offer for first parts, which CERN can then characterize) 10
Status of the analytical study Cu-Alloy Wedges: Another possible contact for the wedges fabrication could be: (contact provided by Spanish Industrial Liaison Office at CERN) –not contacted yet INDUSTA Polígono Industrial Nº III. C/ Palmera nº4. 46.113 Moncada (Valencia). Contact person: Fernando Tatay <fatatay@industa.com> Telf. +34 96 139 98 40 mvl: 674 273 738 e-mail: comercial@industa.com www.industa.com 11
Status of the analytical study Plasma Coating Insulation: 2000€ per set of 14 parts for the plasma coating of the MQXF (1 coil) Scaling by areas as Etienne Rochepault has suggested: MQXF aperture: 150 mm Dipole/quadrupole: 4 layers/2 layers 2 coils per magnet 2 apertures Final price: 10.667€ per magnet Is it possible another kind of insulation for the end spacers? (cheaper) CERN main workshop suggested to contact vacuum group 1/3 x2 x2 x2 x2 12
Status of the analytical study Iron yoke and iron pad laminations: Raw Material: ARMCO Production process: Fine blanking Manufacturing tolerances to be decided Which is the optimum thickness to reduce the cost? Laminations of 5,8 mm could be a good starting point Optimum thickness advice has been requested to BNL contact (C. Manning November 4th-not reply)-contact provided by AK Steel people Calculation of press size will be done Feintool will be contacted 13
Status of the analytical study Iron yoke and iron pad laminations: VoestAlpine contact: Timothy Keppert (tim.keppert@voestalpine.com). He is an expert of steel and can provide always good recommendations on the selection of the material. However, before contacting Tim Daniel suggests to have a word with Etienne, who is in contact with Tim to select the best suited iron/steel for the collars. After understanding the raw material constraints it would good to contact stamping companies like AMV and also start a study on the cost of stamping with the CERN main workshop (Daniel’s suggestion). Elay has been contacted: Meeting at Ciemat facilities on December 20th (budget sent???-information from ELAY) Spanish company involved in: ARMCO laminations for XFEL project Other projects for CERN??? 14
Status of the analytical study Conductor and Wedges Insulation: Experts form CERN has been contacted (they are working on some figures) Impregnation: CTD-101K will be used Price will be required Confirmation regarding resin volume needed (25% of coil volume) has been requested to the 927 workshop (Nicolas Bourcey) Confirmation regarding resin volume needed (25% of coil volume) has been requested also to Helene Felice, Damien Simon and Clement Lorin (answered by Clement: I would say that a value between 25%-33% seems realistic depending on your cable size versus insulation thickness). Daniel’s suggestion: This scaling could be checked and compared with 11 T dipole experience. Remy Gauthier and Sebastien Clement are good contacts. 15
Status of the analytical study Ground insulation: price for Kapton HN 125µm has been required (Isovolta) (500 km length/ 250 mm width) Rough cost estimation for 127µm film x250 mm width: 10,31€/ m 866€/magnet as 6 layers of polyamide are foreseen. 16
Status of the analytical study Aluminum shell: Raw Material: Al alloy Outer diameter: 820mm Thickness: 100 mm Maximum length? Extrusion press for this size available ? Laurent Deparis will be contacted. Contact provided by Spanish Industrial Liaison Office at CERN: (not contacted yet) Euskal Forging: Josu Ortego Deputy Head of Sales Grupo Euskal Forging Mobile: +34 608 70 47 09 Tel.: +34 943 693 449 Fax: +34 943 691 654 josu.ortego@euskalforging.com www.euskalforging.com 17
Status of the analytical study Axial rods and End plates will be calculated using Fernando’s tool (not identified as main cost drivers) 18