Industrialization Activities in the Americas

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Presentation transcript:

Industrialization Activities in the Americas Bob Kephart SRF2011/GDE industrialization Chicago, July, 2011

Introduction Development of SRF capabilities in U.S. Industry has started in support of future SRF based projects. Examples: ILC (by far the largest SRF project considered) JLAB 12 GeV upgrade FRIB Project X (would employ ILC cavities) ERL’s Etc U.S. SRF industrialization is primarily funded with generic SRF and ARRA funds (versus ILC funds) Additional activity is funded by future projects (e.g. above) In this talk I review the current status and plans for: North American industrial fabrication of 1.3 GHz elliptical cavities Industrial fabrication of ILC/PX cryomodule parts Development of an industrial cavity processing capability SRF development for PX There is also additional industrial work on RF power and couplers July, 2011 GDE meeting Chicago

A Possible ILC-SCRF Industrialization Model ILC Host-Lab Technical Coordination (for Lab- Consortium) Marc Ross Slide Regional Hub-Lab: A Regional Hub-Lab: E, & … World-wide Industry responsible for ‘Build-to-Print’ manufacturing by Cavity/Cryomodule Fabricators Sub-component Suppliers Material Venders Regional Hub-Lab: D Regional Hub-Lab: B Comparison with Iter - using the rd phase for tech xfer. Models to be used for construction. Regional Hub-Lab: C: responsible for Hosting System Test and Gradient Performance Note 1: -Regional hub-laboratories are responsible for any regional procurement and must be open for world-wide industry participation - Industry may deliver to any region’s laboratory through procurements above : Coordination link : Procurement link July, 2011

Strategy Develop SRF technology in labs, to the extent possible transfer technology to industry for project construction Motivation for industrial development: Competition: which should lead to improved performance of SRF components and lower prices for future accelerators ( ILC or Project X) Availability: Multiple qualified vendors will ensure product availability in case one vendor ceases operations or has other large contracts Capacity: Promotes increased industrial capacity in preparation for the construction of projects Concern: Timing for industrialization Project timescales (PX and ILC) are still uncertain Once an industrial capability is created it atrophies if not used Concern: Risk vs. cost in industry  Projects assume risks Assume: Labs provide costly cryogenic & RF test infrastructure July, 2011 GDE meeting Chicago

Cavity/CM process and Testing Surface Processing Cavity Fabrication Vertical Testing He Vessel, couplers, tuner HPR or reprocess Horizontal Testing Cold String Assembly Pass! Fail! Pass! Plan… Develop in labs then transfer technology to industry July, 2011 GDE meeting Chicago

ILC Cavity Industrialization 1.3 GHz cavity procurements support Cavity R&D towards the ILC S0 goals (FNAL, ANL, JLAB, and Cornell effort) Construction of CM’s to support ILC S1 & S2 goals Construction of prototype CM’s for Project X Development of qualified cavity vendors All purchases thus far are cavities with the “TESLA” shape But may consider other shapes in the future Vendors of course also acquire valuable SRF experience by fabricating cavities of other shapes and frequencies for projects other than ILC July, 2011 GDE meeting Chicago

U.S. Cavity inventory and planned procurements 3 U.S. Vendors July, 2011 GDE meeting Chicago

Advanced Energy Systems 16 nine-cells delivered & 11 tested; + 20 on order 1.3 GHz Tesla single-cell Electron-beam welding facility 1.3 GHz Tesla nine-cell 1.3 GHz re-entrant nine-cell July, 2011 GDE meeting Chicago

AES cavities Results are very encouraging Batch 1 (4 cavities) (used EBW from another company) Delivered, tested (AES004 at 27 MV/M in S1-global CM) 1 cavity (AES002) at 35 MV/M (recovered by 1st dressed EP) 2 other cavities, limited in 20’s by defects (mostly pits), AES003 repaired by local grinding at KEK and EP at ANL, now 34 MV/M (1st repair by grinding), AES001 ground at KEK, awaits test Batch 2 (6 cavities) (EBW at AES with new welder) Delivered, tested Two cavities with defects (20, 22 MV/M), one recovered to 36 MV/M by CBP Four cavities exceed 35 MV/M ! (41, 41, 36, 38 MV/M) Last four cavities processed with 800 C bake…seems to reduce HAZ pits ? Batch 3 (6 cavities) Delivered being processed and tested, QC looked good but.. Problems with first light BCP at U.S. vendor… pits… not understood Batch 4 ( 20 cavities) Ordered with ARRA funds, Delivery of 10 cavities Fall 2011 July, 2011 GDE meeting Chicago

Niowave & Roark collaborate on 1 Niowave & Roark collaborate on 1.3 GHz cavities Roark is working independently on low-beta structures 6 Single-cell cavities deliver Jun 08 -Performed well 6 nine-cell cavities delivered, being processed and tested 10 ARRA funded 9-cell cavities on order Roark 325 MHz beta=0.22 single-spoke cavity Delivered Summer 2008 Design = 10 MV/M @ 4K Exceeded 30 MV/M @ 2 K Ordered 10 more for Project X have started to arrive at FNAL July, 2011 GDE meeting Chicago

Niowave- Roark 9-cell ILC Cavities 9-cell performance 2 of 6 nine-cell ILC 1.3 GHz cavities processed & tested so far One achieved 29 MV/M The other ~ 17 MV/M Both quench limited by defects, investigating Some weld alignment and QC issues to work through e.g. One HOM notch was off frequency July, 2011 GDE meeting Chicago

PAVAC: Single Cell 1.3 GHz Cavities 6 single cell cavities fabricated Two different methods of welding Smart bell - PAV001-003 First weld together half-cells, then add beam tubes Weld equator from inside Dumb bell - PAV004-006 First weld each half-cell to a beam tube, then weld together Two “smart bell” cavities tested so far, both exhibit multi-pacting Small changes in cell shape from die? A result of unusual weld technique? “Dumb bell” cavities will be tested soon ARRA order for ten 9 cell cavities awaits success on single cells July, 2011 GDE meeting Chicago

ILC PX Not Shown 1 more AES >35 @JLAB New vendor 1st BCP AES AES replaced damaged end group on A12. CBP then EP A15 Repaired by CBP 2034 AES002 repaired by dressed EP 33 AES003 repaired at KEK by grinding34 AES006 repaired by CBP to 35 AES005 repaired tumbling@Cornell to 31 ILC PX Not Shown 1 more AES >35 @JLAB JLAB & ANL/FNAL facility contributing heavily to ILC gradient program Pits in EB weld HAZ New vendor 1st BCP AES

U.S. Plan for Cavity Vendor Development Vendors learn through experience, so in general they will improve their manufacturing processes over time But, feedback from the laboratories is key to obtaining performance improvements Careful QA and optical inspection of incoming cavities Process & test cavities quickly Relatively small cavity orders allow for feedback between production batched Larger orders will allow us to better understand costs Keys to success Close communication and regular visits Assistance from experts at FNAL, Cornell, JLab, ANL, DESY, KEK, etc Learning how to repair cavities ! Stimulus procurements have given cavity vendors a big boost But concerns about how we sustain this effort in the future July, 2011 GDE meeting Chicago

Industrial Surface Processing Industrial electro-polish ARRA funds make it possible for us to fund electro-polish capability in U.S. industry Competition to perform design study; AES won the bid AES is in the process of constructing a EP facility Capable of processing 1300 and 650 MHz elliptical cavities Benefits from existing clean room, HPR, and chemistry infrastructure funded at AES by Brookhaven National Lab Eco-friendly surface processing Funded with ARRA funds Goal is to produce smooth clean cavity surfaces without using HF and other toxic chemicals 2 companies selected (Faraday bipolar EP, Cabot =CMP) Work in progress Centrifugal Barrel Polish is under further development at Fermilab Several 9-cells have achieved ILC gradient after CBP & light EP Potential to dramatically reduce hazardous acid use Technique is easily transferable to industry July, 2011 GDE meeting Chicago

U.S. Industrialization of Cryomodules Strategy on Cryomodule Industrialization The value added during CM assembly is < 10% the value of the cryomodule. However the risk is high! The number we will assemble over the next few years is very small  have no plans to train industry to do assembly of ILC CM Any training likely to be lost… without follow on work Not even clear this would make sense for Project X Strategy is to design cryomodules at labs, order parts from industry, assemble & test at Fermilab ILC may require a different strategy Currently testing CM1 (DESY kit) & assembling CM2 July, 2011 GDE meeting Chicago

Cryomodule 1 Testing in Progress -7 cavities are powered simultaneously from 5 MW klystron using SLAC RF dist system -Tuner motor failure so powered 8 by itself Preliminary - 2 with high heat; no FE? - Calibrations under study July, 2011 GDE meeting Chicago

Dressing cavities for CM2 Cryomodule activities at FNAL Final Assembly MP9 Clean Room CM2 String Assembly CM1 Move to NML FNAL S1 global Cavities @ KEK CM1 installed Dressing cavities for CM2

U.S. Industrialization of Cryomodules CM3-6 Parts He Vessels: Fabricated of Titanium (like XFEL) 20 already procured from Hi-Tech 40 more being procured with ARRA funds from INCODEMA Tuners For CM2 and beyond we will use Blade tuners developed by INFN CM2 and S1-Global: 12 tuners provided by INFN, built in Europe CM3-CM6: Tuners made by U.S. industry (ARRA) 20 Titanium blade tuners from INCODEMA; 20 from Hi-Tech Have dressed 18 ILC cavities… July, 2011 GDE meeting Chicago

U.S. Industrialization of Cryomodules CM3-6 Parts Couplers (1300 MHz, TTF type) Vendor is Communications and Power Industries, CPI SLAC inspects, tests, and conditions couplers for Fermilab 44 couplers ordered and delivered to SLAC ~ half at Fermilab and installed in dressed cavities Cold mass parts and Vacuum Vessels 4 cryomodules worth of Type IV parts - delivered Vendor: PHPK Technologies July, 2011 GDE meeting Chicago

New Cryomodule Test Facility (ARRA funded ) New 500 W 1.8 K refrigerator (under fabrication in industry) will be located in CMTF bldg New Electronics building above tunnel extension New Cryomodule Test Facility Compressor building July, 2011 GDE meeting Chicago

Project X & SRF industrialization 3 GeV High Intensity Program (2.8 MW) 3 GeV CW SRF Linac 1 ma H- or Protons Recycler Linac: 1 mA x 5 ms @ 10 Hz 5 pulses per fill 3  8 GeV Pulsed Linac (or RCS) Stripping foil 8 GeV fast spill (200 KW) 2.2 x 10 14 Protons / 1.4 sec LBNE (2 MW) 120 GeV Fast extraction 1.6 x 10 14 Protons / 1.4 sec Main Injector 1.4 Sec cycle Single turn transfer At 8 GeV 3-8 GeV linac would be 1300 MHz pulsed retains synergy with ILC R&D but gradient ~ 25 MV/M July, 2011 GDE meeting Chicago

PX SRF Linac Technology Map b=0.11 b=0.22 b=0.4 b=0.61 b=0.9 325 MHz 2.5-160 MeV b=1.0 1.3 GHz 3-8 GeV ILC 650 MHz 0.16-3 GeV CW Pulsed Section Freq Energy (MeV) Cav/mag/CM Type SSR0 (G=0.11) 325 2.5-10 18 /18/1 SSR, solenoid SSR1 (G=0.22) 10-42 20/20/ 2 SSR2 (G=0.4) 42-160 40/20/4 LB 650 (G=0.61) 650 160-460 36 /24/6 5-cell elliptical, doublet HB 650 (G=0.9) 460-3000 160/40/20 ILC 1.3 (G=1.0) 1300 3000-8000 224 /28 /28 9-cell elliptical, quad July, 2011 GDE meeting Chicago

Things that are Going Well Cavity vendors are engaged and have orders ARRA (Stimulus) allowed us to make a start at industrialization Some U.S. cavity vendors are fabricating world class ILC cavities Vendors for other cavity and cryomodule parts are established A matter of finding the right vendor for the type of work required International vendors have contributed to our progress e.g. ACCEL/RI cavities have allowed U.S. to validate process and test infrastructure Have seen Openness with regards to fabrication techniques (non-disclosure) Willingness to deal with problems as they arise Creativity WRT cavity repairs Urgency to complete projects on time Intellectual investment July, 2011 GDE meeting Chicago

Things that could use Improvement Consistency of fabrication / higher yields EBW associated defects still are not fully understood & under control Quality Control and Documentation Dimensional accuracy is less than ideal from some vendors Sometimes a mistake is made on a first article… understandable… but then not recognized and repeated multiple times.. Key to achieving high yield is controlling the fabrication processes Need better documented and accessible fabrication records Communication Labs need to know when industry is having problems – we can help Industry needs to provide feedback to Labs regarding our designs and specifications – we need to listen Still looking for innovation  a better way to do things Cost of SRF based accelerators is still too high Value Engineering in industry can help July, 2011 GDE meeting Chicago

Summary Fermilab is engaged in vendor development with three North American cavity vendors. Also engaged in industrialization of cryomodule parts, surface processing, RF equipment Industrialization is being funded by ARRA funds but one time infusion of funds U.S. participation in the construction of ILC would require a large scale up of these efforts Likely that, Project X or other similar projects are the near-term path to U.S. SRF industrialization for a future ILC project July, 2011 GDE meeting Chicago