High Order correctors coil manufacturing Marco Statera on behalf of the LASA team CERN 20/4/2016

SUMMARY ground insulation test coils and 6pole coils coils after a cooldown cycle 20/4/2016 M. Statera

GROUND INSULATION: COILS measured in a single point up to 5 kV impedance [TW] S1 1.66 S2 1.75 S3 1.95 S4 1.36 S5 0.765 S6 1.50 TC5 1.77 20/4/2016 M. Statera

GROUND INSULATION: 6POLE VOLTAGE ASSEMBLY LOW TEMPERATURE (16-19/2 test) ROOM TEMPERATURE no return flux insulation after welding N2 G 90 K He L HE G 24 K after the test no return flux – connections side 250 V 18.6 GW 93 GW 500 MW 17.8 GW 500 V 113 GW 1.97 GW 940 MW 960 MW 250 MW 7.3 GW 1000 V 124 GW 1.14 GW 1.02 GW 555 MW 2000 V 120 GW 1.01 GW 20/4/2016 M. Statera

HIGH VOLTAGE INSULATION G10 wires-iron stainless steel support PFTE tubes wires-stainless steel support 20/4/2016 M. Statera

WIRES INPUT - OUTPUT stainless steel spacer stainless steel ring G10 20/4/2016 M. Statera

KAPTON® INSULATION discharge @ 2 kV 20/4/2016 M. Statera

BUS BAR CONNECTION 0.3 mm G10 20/4/2016 M. Statera

CONCLUSIONS each coil tested @ 5 kV sextupole tested during installation, at low temperature and again at room temperatuture the electrical connections circuit and connection have to be optimized 20/4/2016 M. Statera

TESTED COILS TC4 G10 TC5 ULTEM™ TC6 DURATRON© S8 G10 20/4/2016 M. Statera

TESTED COILS material windings dimensions mm x mm TC4 G10 204 88 x 126 ULTEM™ 174 TC6 DURATRON© 170 88 x 132 S8 216 20/4/2016 M. Statera

G10 COILS mechanical properties minimun thickness machinable TC4 S8 S2 tape filling TC4 mechanical properties minimun thickness machinable 0.2 mm G10 inner 0.2 mm G10 G10 1.0 mm outer 0.2 mm G10 S8 S2 tape and G10 are placed after the winding 20/4/2016 M. Statera

ULTEM™ COILS 1.2 mm 1.2 mm 3D printed shape on demand 3D structure resin penetration 20/4/2016 M. Statera

DURATRON© COILS bulk machinable mechanical properties 1.3 mm 1.3 mm 20/4/2016 M. Statera 1 mm 1.50-1.55 mm

TECHNOLOGIES PRO’S CON’S G10 glass epoxy laminate mechanical propertiess minimum thickness machinable radiation hardness ULTEM™ polyetherimide (PEI) 3D printed shape on demand 3D structure resin penetration low mech properties print time min thickness DURATRON© PEI- 30% glass fiber easy machining mechanical propertiess high cost BTS2 by Arisawa Bismaleimide- Triazine resin – S2 laminate (less easy than G10) thin foils mechanical properties same technology as G10 very high cost 20/4/2016 M. Statera

TRAINING TC4 4.2 K 2.5 K 20/4/2016 M. Statera

TRAINING TC5 ULTEM™ training not negligible 4.2 K 2.2 K 20/4/2016 M. Statera

TRAINING TC6 DURATRON© no training 4.2 K 2.2 K 20/4/2016 M. Statera

TRAINING S8 no training 4.2 K 2.2 K 20/4/2016 M. Statera

TRAINING OVERVIEW I/IC 20/4/2016 M. Statera

TRAINING OVERVIEW 2 temperature 4.22 K temperature 2.17 K Bmx [T] on coil IC Imx/IC Bmx[T] TC4 2.909 289.95 0.907 3.7683 375.58 0.797 @2.5 K TC5 2.752 302.41 0.990 3.5664 391.95 0.944 TC6 2.620 313.47 0.948 3.3985 406.39 0.906 S8 2.923 288.87 0.962 3.7859 374.21 0.925 20/4/2016 M. Statera

DID THE COILS SURVIVED? TC4 ok TC5 ULTEM™ damaged G10 technology commissioned TC5 ULTEM™ damaged low modulus TC6 DURATRON© small defects epoxy delamination (thin layer) small cracks in bulk epoxy S8 ok cracks on heater 20/4/2016 M. Statera

WINDING QUALITY TC5 ULTEM™ TC6 DURATRON© @CERN @LASA edms n. 1554721 M. Crouvizier S. Sgobba TC6 DURATRON© @LASA D. Pedrini A D C B E F H G 20/4/2016 M. Statera

TC5 TRANSVERSE CUTS dimensions not optimized quite symmetric arrangement dimensions not optimized outer resin thickness (coil specific) cracks perpendicular to surface stops in the area between Ultem™ and glass fiber surrounding the wires 20/4/2016 M. Statera

TC5 LONGITUDINAL CUTS cracks no cracks between wires perpendicular to surface through Ultem and resin stops in the area between Ultem and glass fiber surrounding the wires no cracks between wires epoxy-Ultem detaching in some spots L3 L2 20/4/2016 M. Statera

TC6 DURATRON© STRAIGHT thin section (few mm) stacking not perfect no resin detaching 1 void wires-duratron stacking not perfect inner dimension not optimized duratron deformation during impregnation C H 20/4/2016 M. Statera

TC6 DURATRON© BEND some voids one crack appeared after 2 days LEICA stereoscope some voids impregnation to be improved one crack appeared after 2 days stress release no epoxy detaching 20/4/2016 M. Statera

HOW DID THE COILS PERFORM? all coils showed good maximum current G10 good performance low radiation hardness ULTEM™ training did not survive the cooldown DURATRON© adhesion to be crosschecked BTS2 same technology as G10 the resin adhesion still not tested NEXT STEPS resin adhesion test octupole coils: DURATRON© material is in house decapole coils: BTS2 material ordered the mechanical and electromagnetic design can be fit to both materials 20/4/2016 M. Statera

TENSILE SHEAR STRENGTH compare the CTD101K adhesion G10 DURATRON© BTS2 glued area: 4 mm x 15 mm inspired to tensile shear test ISO 4587: Adhesives -- Determination of tensile lap-shear strength of rigid-to-rigid bonded assemblies ASTM D3165-07: Standard Test Method for Strength Properties of Adhesives in Shear by Tension Loading of Single-Lap-Joint Laminated Assemblies The BTS2 material to prepare the specimens is kindly supplied by Dr Nakamoto and his team at KEK Some material is still available: it may be used for other tests, to be agreed with Dr Nakamoto 20/4/2016 M. Statera

SPECIMENS room temperature tests 1 G10, 2 DURATRON© and 2 BTS2 cooled at 77 K and then tested at room temperature 2 DURATRON© and 2 BTS2 specimens ready to be glued 20/4/2016 M. Statera

CONCLUSIONS each coil tested @ 5 kV sextupole tested during installation, at low temeprature and again at room temperatuture the electrical connections circuit and connection have to be optimized two coils’ construction technologies tested compared to G10 coils 3D printed ULTEM™ not suitable bulk DURATRON© coils will be installed in the octupole BTS2 instead of G10 resin adhesion will be tested soon to be installed in decapole adhesion test to compare G10, DURATRON© and BTS2 in preparation 20/4/2016 M. Statera