LCLS Vacuum System Plans (July 07) 5/25/2019 LCLS Vacuum System Plans (July 07) Lehman Review July 10th-12th 2007 Test

Aluminum Extrusion (Primary Design) Prototyping - started in earnest after the last Lehman Review in November 06 Emil Trakhtenberg - Responsible for development so far : see Feb 22nd report – “Aluminum Extrusion as an Option for LCLS Undulator Vacuum Chamber” and PAC 07 paper “A Study of the minimum wall Thickness for an extruded Aluminum Vacuum Chamber” >50 full length extrusions at ANL – Surface finish achievable ~200 -500nm so far. Surface finish development running in parallel with full length machining Machining and welding on short samples – full length prototype by mid August July 07 Pat Den Hartog (APS) – Responsible for production of Chambers Greg Wiemerslage - Production Engineering Mark Erdman - Quality Engineering - Specs, Procedures & Docs Joe Gagliano + 3 - Welding and Vacuum system assembly

>50 full length extrusions at ANL

Full Length Prototype highlights: AL Extrusion Schedule Full Length Prototype highlights: Existing surface finish : 200 -500 nm Polished samples arriving now - 3 more leaving ANL for EFC now. Expect 2nd iteration results by 7/30/07 Citrinox cleaning has little or no effect Surface finish degradation of 1-3nm @85nm Full length Chamber with wall @ 0.5mm - Fully machined chamber ~7/25/07 Welding, cleaning, baking and vacuum testing ~ mid August 07 Prototype evaluation complete by end of August 07

Early AL Extrusion Prototype results

AL Extrusion Production Schedule QA chambers first five 12/4/07 12/6/07 Pre-cleaning of first five 12/7/07 12/7/07 Weld prep, weld and leak check first five 12/10/07 12/14/07 Post cleaning first five 12/12/07 12/17/07 Bake first five Chambers 12/14/07 12/20/07 Leak check and RGA first five 12/17/07 12/21/07 Ship first five chambers to SLAC 1/7/08 1/10/08 First Five Chambers at SLAC 1/7/08 1/10/08 (SS schedule 11/19 -11/26)

AL Extrusion Production Schedule Estimate V’s Existing SS Vac Chamber Schedule SS Vacuum Chamber Lot (A ) 10/26/07 12/26/07 (4) Ship to SLAC 1/2/08 AL Vacuum Chamber Lot (A ) (5) Ship to SLAC 1/10/08 SS Vacuum Chamber Lot (B ) 11/28/07 1/07/08 (7) Ship to SLAC 1/14/08 AL Vacuum Chamber Lot (B ) (5) Ship to SLAC 1/21/08 SS Vacuum Chamber Lot (C ) 1/02/08 1/31/08 (7) Ship to SLAC 2/7/08 AL Vacuum Chamber Lot (C) (12) Ship to SLAC 2/19/08 SS Vacuum Chamber Lot (D) 1/31/08 3/03/08 (7) Ship to SLAC 3/11/08 AL Vacuum Chamber Lot (D ) (12) Ship to SLAC 3/26/08 34 Available SS Vacuum Chamber Lot (E) 3/03/08 3/31/08 (8) Ship to SLAC 4/2/08 33 Available AL Vacuum Chamber Lot (E ) (12) Ship to SLAC 4/16/08 AL Spares SS Vacuum Chamber Lot (S) 3/19/08 4/09/08 (4) Ship to SLAC 4/16/08 SS Spares

AL Extrusion Costs Item Cost per Chamber Total Cost/40 Cost based on $210.31 $8,412.51 actual order received(PO# 7a-02242) Chamber Machining $6,200 $248,000 first two articles from Hi-Tech $15k Quote #101274 from Metalex 4792.5 ea bi-metallic flanges $1,000 $40,000 Engineer's experience attachment to strongback $1,500 $60,000 based on quote surface finish improve 1500 for abrasive flow or EP based on early vendor consults $3,000 if both are needed $120,000 weld fixturing costs $7,000 based on previous experience shipment crating cost Sub Total $544,912.51

Engineer's estimate and experience 48 hours (no effort charged) AL Extrusion Costs Effort Item Hours per chamber Total hours/40 Cost Based on QA 4 hours 160 Engineer's estimate and experience cleaning 8 hours 320 weld prep 2 hours 80 welding 3 hours 120 post weld leak check post weld cleaning bake-out prep bake-out 48 hours (no effort charged) 1920 leak check and RGA assemble strongbacks shipping prep Average Tec/Eng rate ~$100/hr Total hours 1720 Sub Total $17,200 Total Cost $562,112.51

AL Extrusion plan achieves Cost and Schedule Stainless Procurements Alloy 20 $115815 Side Wall $140600 End Cap $119621 Strongback – Machining $604321 Total Cost SS procurements $980357 (in procurement on hold) Total Cost AL Extrusion $562112 (Estimate) SS Vacuum Chamber Lot (A ) 10/26/07 12/26/07 (4) Ship to SLAC 1/2/08 AL Vacuum Chamber Lot (A ) (5) Ship to SLAC 1/10/08 AL Vacuum Chamber Lot (D ) (12) Ship to SLAC 3/26/08 34 Available SS Vacuum Chamber Lot (E) 3/03/08 3/31/08 (8) Ship to SLAC 4/2/08 33 Available http://www-ssrl.slac.stanford.edu/lcls/project_home.shtml for info on sharepoint

Copper tube Vacuum Chamber Back-up Plan Copper tube Vacuum Chamber

Copper Tube Prototype and Production (BACK-UP) Prototype work starting now – drawings and materials 4 weeks for production of parts 2 weeks for assembly, bake-out and vacuum tests Second Vacuum Shop Crew available: John Hoyt + 3 - Brazing and Vacuum system assembly Evaluate end of August 07 with Extrusion

Revised Copper Chamber Design The existing LCLS Vacuum group has quickly changed directions going from the Stainless Steel design to the Copper Chamber The group is enthused to support the copper chamber.

Copper Tube Design from April 2004

Copper Tube Design from April 2004

Design Description Copper Tube (alloy 110) drawn into the shape of a 12 mm X 5 mm (ID) oval Flanges and mounting blocks are joined to the tube. The use of Ag-Sn-Cu solder has been successfully used on vacuum chambers in the past. Tube is polished using singularly or in combination: electro-polish and abrasive flow machining (this is also being used on the aluminum extrusion). The copper tube will be bolted to the strongback The strongback is made of 6061 aluminum to reduce cost and effort. The copper tube will use the same sputtering technique that was developed for the internal aluminum coating of the stainless steel chamber. This assembly will be bakable to 150oC for beamline use.

Design Description Copper Tube (alloy 101) drawn into the shape of a 5 mm (ID) X 6 mm round Flanges and mounting blocks are joined to the tube. The use of Ag-Sn-Cu solder has been successfully used on vacuum chambers in the past. Tube is polished using buffed drawing dies. The copper tube will be bolted to the strongback The strongback is made of 6061 aluminum to reduce cost and effort. This assembly will be bakable to 150C for beamline use.

Copper Chamber Design 2007 Copper Chamber bolted to an aluminum strongback.

Copper Chamber Design Piece parts have been reduced to drawings

Cost for Prototyping Total $10, 300 These are ANL Central Shops costs and schedule WITHOUT any polishing costs. That will be handled by the ANL team This will not use an oval tube, a round tube is obtainable in 4 weeks for $750. Prototype Schedule: 4 weeks to build parts 1-2 weeks for assembly and baking Completion ~6 weeks

Round Tube Costing Prototype Tubing (2) Pieces will cost $750 Copper tubing vendor has stated in the past that they can improve the surface finish to a 12 in. They need more time to work this out.

Oval Tubing Cost Production Tubing Copper tubing vendor has stated in the past that they can improve the surface finish to a 12 in. They need more time to work this out. Total cost for 40 units= $6,680

Production Costs Vacuum factory work: Cleaning 4 units per day The costs for the strongback, surface finish, and the flange weldments appear to be overstated at this point. As this develops, these costs will be updated. Vacuum factory work: Cleaning 4 units per day Assembly 4 units per day Bake out - Leak Checking 3 units per week Testing 2 units per day Effort cost for 18 hours= $2,160 ea. Piece Part Cost $8,525 Overall Cost $315,433

Production Schedule First Unit -Nov. 15 Last Unit for Installation- Mar. 15

Organization Responsible Engineer is Soon-Hong Lee Supporting Engineers are James Morgan and Dean Walters Coating support technician is Guy Harris Design support is Scott Doran Brazing and Vacuum system assembly is John Hoyt + 3