Analytical Cost Model (16 T dipole) T. Martínez, J. Munilla, F. Toral - CIEMAT Progress Meeting #, November 2nd, 2016

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 7

Status of the analytical study Cu-Alloy Wedges: Our estimation basis on Luvata’s figures: 561 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?) Material: 561kg x 90 €/kg= 50.490 € per magnet COST DRIVER Mat. Area mm2 quantity 1 dipole mass pcs length mm quantity 1 dipole mass meter kg/m quantity 1 dipole mass kg Wedge 6 62,32 64 1.750 112 0,56 63 Wedge 10 60,89 0,55 61 Wedge 1 43,77 0,39 44 Wedge 2 39,55 0,35 40 Wedge 3 47,62 0,43 48 Wedge 4 49,54 0,44 50 Wedge 5 41,95 0,38 42 Wedge 7 78,27 0,70 79 Wedge 8 51,24 0,46 51 Wedge 9 83,97 0,75 84 559,12 mm2   561 8

Status of the analytical study Cu-Alloy Wedges: Luvata proposal: Prototype phase: 10 pieces (1.750mm long) of each profile wedge Production Phase: tolerances, measurements of dimensions, mechanical properties and testing, straightness, surface quality and other mechanical items to be agreed (no price quotated#90€/kg estimated but not confirmed) 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) 9

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 10

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 will be request to BNL contact Calculation of press size will be done Feintool will be contact 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) 11

Status of the analytical study Ground insulation: price for Kapton HN 125µm has been required (500 km length/ 250 mm width) Rough cost estimation for 127µm film x250 mm width: 10,31€/ m 866€/magnet as 6 layers of polymide are foreseen. 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. 12