X-FEL linear accelerator cryomodule integration LCWS, Strasbourg, the 26th October 2017

ALSYOM a subsidiary of ALCEN Group X-FEL cryomodule integration X-FEL accelerator Cryomodule description ALSYOM Industrial mission

ALSYOM : a subsidiary of ALCEN Group An Intermediate Size Company created in 1988 : Industry and Innovation High Technology activities dedicated to following domains: Defence and Security Energies Aeronautic Medical Equipment Large Research Infrastructure Main figures: About 31 subsidiaries in France and North Africa 2016 turnover ≈ 215 M€ 2016 employees ≈ 1 900 350 in Design Office 1 300 in Production ALCEN has a permanent innovation policy applied to its product and services

ALSYOM : domains of activities Experimental Nuclear Fusion Reactors ITER, RJH High Power Lasers Laser Megajoule, PETAL ELI (Extreme Light Infrastructure) Accelerator X-FEL Astrophysics Astronomy (CTA) Aeronautic, Defense and security Turret, satellite antenna and aero structure tools « Program Management, Design, Engineering and Manufacturing » for the production of mechanical and opto-mechanical equipment

ALSYOM : main expertise Development and industrialisation Mechanical, Opto-mechanical, Optic, electronic, command control Design, in collaboration with SEIV design office Product and Process Industrialisation System and Equipment manufacturing Series equipment and complex system production, including: High accuracy mechanism, control command electronic, Optic and cabling Opto-mechanical system in cleanliness and vacuum environment Integration and cleaning Geometrical characterisation Cleaning and integration in ISO 5 and ISO 8 condition Assembly, Integration and test Services Installation on Customer site, including cleanliness, welding and tests Optical Surface Treatment « sol-gel » Maintenance: mechanism, opto-mechanism, vacuum Unique Industrial entity in France grouping these expertise and combined performances High accuracy, large Dimension, Cleanliness and Vacuum

ALSYOM : location in France Paris Tarbes Le Barp LASERIS Bordeaux Cadarache VERSAILLES ALSYOM Headquarter TARBES Bordeaux LASERIS & LMJ

ALSYOM, subsidiary of ALCEN Group X-FEL cryomodule integration X-FEL linear accelerator Cryomodule description ALSYOM industrial mission

X-FEL linear accelerator Construction and installation of the European X-ray Free Electron Laser (E-XFEL). Location : DESY (Deutsch-Elektronen-Synchrotron) in Hamburg (Germany) Tunnel : ~ 1,6 km length 5 X-ray beams 10 experiment stations (research in biology, chemistry, nanotechnology, …)

X-FEL linear accelerator Description of the X-FEL Accelerator Linac (Energy : 17,5 GeV)

X-FEL linear accelerator Institutes involved in the construction of the E-XFEL accelerator

ALSYOM, subsidiary of ALCEN Group X-FEL cryomodule integration X-FEL linear accelerator Cryomodule description ALSYOM Industrial mission

X-FEL Cryomodules E-XFEL accelerator main components

X-FEL Cryomodules 496 types of parts E-XFEL Cryomodule - Main Components 496 types of parts

ALSYOM, subsidiary of ALCEN Group X-FEL cryomodule integration X-FEL linear accelerator Cryomodule description ALSYOM Industrial mission

ALSYOM mission Environment Industrialization ALSYOM Responsabilities Domain of expertise and responsibilities : Industrialization and process definition Assembly, Integration and test activities : production team management ALSYOM Responsabilities Environment Industrialization Methods Machines Deliver 100 cryomodules Meet deadlines Manage the documentation (Quality, Traceability…) Process Improvement Customer Satisfaction INTEGRATION PROCESS Materials People

ALSYOM mission Integration process organized in 7 workstations Cold Coupler Area – (ISO4-CC-WS) Coupler Cold Part assembly + 1 Gate valve Leak tests / RGA tests (RGA : Residual Gas Analysis) String Assembly Area – (ISO4-SA-WS1, ISO4-SA-WS2 ) Connection of the 8 cavities + 1 Quadrupole Leak tests / RGA tests Roll Out Area – (RO-WS1, RO-WS2) 2 Phase Pipe welding + tests (VT, LT, PT, RT) Temperature sensors, magnetic shields, 4K & 70K assembly Tuner systems assembly + RF controls Cold Mass positioning and hooking Alignment Area – (AL-WS1, AL-WS2) Alignment of the cavities/Qpole with the cold mass (~ 100µm) 8mm pipe welding + tests (VT, LT, PT) Electrical tests (Tuners & piezo systems) Current leads welding Thermalization

ALSYOM mission Integration process organized in 7 workstations Cantilever Area – (CA-WS) 4K & 70K shells welding Cables positioning and thermalisation Introduction inside the vacuum vessel ; fixing Alignment Cold Mass / vacuum vessel Coupler Area – (C0-WS1, CO-WS2) Coupler warm part assembly + Leak test Coupler Pumping Line assembly + Leak test T° sensors and Motors cabling Current lead connection + Electrical tests Current lead welding on the vacuum vessel + Leak Tests Cavity string pumping + final Leak test & RGA Shipment Area – (SH-WS1, SH-WS2) End caps positioning on the vacuum vessel Pumping and Nitrogen flushing RF controls, Motors controls Connection of the vacuum recording box for transportation Loading on truck

ALSYOM mission Integration process organized in 7 workstations

ALSYOM mission ALSYOM industrial team Production activities Up to 33 people Management and Quality Integrator in clean room Welder and coordinator RF, laser tracker, vacuum test technician Logistician Production activities Supply Chain Production Flow management Technical event management : from the problem to the solution Transverse activities Quality management Documentation management Configuration management

RESULTS Complete production cycle for ONE Cryomodule : 7 weeks Schedule and production rate 4 years divided in 3 Phases Training and Process definition (3 prototypes) Ramp Up to reach the rate of 5 days Series Production (100 cryomodules) with rate acceleration up to 4 days Complete production cycle for ONE Cryomodule : 7 weeks Up to ONE Cryomodule every for 4 days, ready for delivery

RESULTS Schedule and production rate achieved Performance achieved for the 100 Cryomodules

X-FEL inauguration in Hamburg

Welcome in the South West of France Thank you for your attention Thierry HOVSEPIAN Managing Director Eric GIGUET Commercial and Development Director ALSYOM 17 Bis Avenue des Forges CS 20125 65 001 Tarbes Cedex - France Tel.: +33 (0)562 446 700 Fax: +33 (0)562 446 701 www.alsyom-alcen.com Welcome in the South West of France