Undulator and Magnet Production Status 25 October 2006 8/1/2019 Undulator and Magnet Production Status 25 October 2006 Titanium Strongbacks 1.04.03.03.01 Magnet Blocks 1.04.03.03.02 Magnet Poles 1.04.03.03.03 1st-Article Assemblies 1.04.03.03.04 Production undulators 1.04.03.04.01 1.04.03.04.02 Support & Motion System 1.04.03.04.03 Quadrupole magnets 1.04.03.05.01 Test

Need 40 Titanium Strongbacks 1.04.03.03.01 20 from Metalex – Blue Ash, OH All 20 were complete and accepted in August. 20 from Dial – Rockford, IL 11 completed.

Acceptance of strongback #20 at Metalex

Magnet Poles 1.04.03.03.03 Fabricated by Hi-Tech Mfg., Schiller Park, IL All 19,200 magnet poles were completed in September.

The Last Pole #19,200 at Hi-Tech

Magnet Blocks 1.04.03.03.02 Fabricated by Shin-Etsu in Japan. 26 of the 40 magnet lots are delivered. QA sample magnets are checked through 28 lots and approval was granted to ship 27 & 28. They are behind – meeting was held 4th of October at Argonne to prod them. All remaining magnets are pressed; finishing machining and plating now. Expect raw data and QA samples for 2 lots, 29 & 30, in October. Remaining 10 lots expected by end of this year.

APS Measurements Still Agree with Shin-Etsu

1st-Article Assemblies 1.04.03.03.04 Required: 2 1 from Hi-Tech – Schiller Park, IL Completed on time, factory accepted 13 March 2006, tuned at ANL. Still at Argonne; used in the SUT. 1 from Metalex – Blue Ash, OH Completed on time, factory accepted 30 March 2006, tuned at ANL. Delivered to SLAC.

Hi-Tech 1st Article Acceptance 13 March 06

Metalex 1st Article Acceptance

Thirty-Eight (38) Production Assemblies 19 from Metalex – Blue Ash, OH 1.04.03.04.01 Six are accepted to-date; will ship to SLAC next week; many parts ready for assembly of the rest; 6 more assemblies are expected by the end of this year. 19 from Hi-Tech – Schiller Park, IL 1.04.03.04.02 Eight are accepted to-date; six are at SLAC. All parts are ready for the remainder; assembly held up by slow strongback delivery from Dial [planned remedy]; 6 more assemblies are expected by the end of this year.

Production @Hi-Tech – Staged Mechanical Parts

Magnets Sorted and Staged for Assembly at Hi-Tech

Peak-Field Acceptance Measurements @Hi-Tech

Go / No-go pole-gap verification @Metalex

Strongbacks Staged for Assembly @ Metalex

Peak-Field Acceptance @ Metalex

QA/Docs Check @Metalex – Everything’s In There

Support & Motion System 1.04.03.04.03 Prototype or Ersatz units were constructed and assembled in MM1. The assembled system, together with readout and controls, was extensively tested in the Single Undulator Test (SUT) [Details in Geoff Pile’s talk] We are in the process of finalizing all drawings and assembling the statement of work in preparation for issuing the RFQ.

Final Design Review – 14-15 September 2006 The final design review of the LCLS undulator support and motion system was a milestone along a long path that has taken some years to travel. Prototype undulator constructed, measured, tuned, and studied over several years at ANL Prototype support – designed and tested; experience with the prototype led to the final SUT design. Single Undulator Test [SUT] - almost all components were assembled and integrated for the SUT; measurement equipment and techniques, motion verification, control and monitoring, analysis, thermal stability, noise, …

Support / Motion System: Quote from FDR Report Exemplary performance is evident in a very difficult interdisciplinary design and development project. The committee is particularly impressed by the rigorous testing of the prototype system and the modeling of proposed improvements. The thorough benchmarking of the current system allows informed decision-making for related technical and logistical areas. The procurement approach as envisioned is sound. The magnitude of the logistical challenge in providing these systems has been thoroughly considered by the presenters.

The Plan The closer we are to being able to deliver a complete unit to SLAC, the more likely it is that we will all succeed to get a high-quality product installed in the tunnel on schedule. Preassembled and checked out systems delivered to SLAC Any required tests documented All parts inspected and documented Assembly verified May or may not need to partly disassemble into several large pieces [FS, Girder, Interface plate] to pack for shipment. Saves time at SLAC. Effort that would otherwise have to be devoted to this could be used for more urgent tasks.

Preparations We invited a couple of vendors to come to ANL and have a look at the SUT. Their impressions are that this is well within their means to assemble, and will not be all that complicated. We envision a build-to-print with, perhaps, some GFE. First articles will be constructed and evaluated by ANL prior to granting permission to proceed. Splitting the procurement between two vendors is a philosophy that was successfully used before to mitigate risk. It will be applied here as well. The LCLS schedule calls for an award in early FY07 and completion of the contract by the end of FY07.

Schedule Act ID Description Early Start Early Finish Late Start Late Finish UN33_40305 AWARD: Support/Mover System 1st 2 Articles 1-Nov-06 29-May-07 UN33_40310 Vendor Prep & Documentation-Support/Mover System 2-Nov-06 16-Nov-06 30-May-07 13-Jun-07 UN33_40315 Construction 1st Two Articles - Suppt/Mover Sys 17-Nov-06 23-Jan-07 14-Jun-07 9-Aug-07 UN33_40320 Factory Accept Testing - Support/Mover System 24-Jan-07 30-Jan-07 10-Aug-07 16-Aug-07 UN33_40321 Ship 1st 2 Articles Support/Mover System to ANL 31-Jan-07 6-Feb-07 12-Feb-10 18-Feb-10 UN33_40322 REC: 1st 2 Articles Support/Mover System at ANL 7-Feb-07 19-Feb-10 UN34_00012 Evaluate 1st 2 Articles Support/Mover 8-Feb-07 8-Mar-07 22-Feb-10 22-Mar-10 UN34_00017 ACCEPT: 1st 2 Articles Support/Mover UN34_00018 Ship 1st 2 Articles to SLAC 9-Mar-07 22-Mar-07 23-Mar-10 5-Apr-10 UN34_00019 RFI: 1st 2 Articles Support/Mover UN34_00015 AWARD: Support/Mover Production Units (37) 14-Feb-07 31-Aug-07 UN34_00006 Renegotiate Contract for 36 Suppt/Mover System 15-Feb-07 4-Sep-07 UN34_00007 Permission to Proc w/Rem 36 Supt/Mover Systems UN34_00014 Vendor Fab Support/Mover Production Units 16-Feb-07 18-Sep-07 5-Sep-07 14-Apr-08 UN34_00047 RCV: Support/Mover Lot 1 (9 units) 20-Apr-07 25-Mar-08 UN34_00048 RCV: Support/Mover Lot 2 (10 units) 18-May-07 UN34_00049 RCV: Support/Mover Lot 3 (4 units) 18-Jun-07 UN34_00051 RCV: Support/Mover Lot 4 (3 units) 17-Jul-07 24-Mar-08 UN34_P0052 RCV: Support/Mover Lot 5 (2 units) 18-Jul-07 UN34_00149 RCV: Support/Mover Lot 6 (3 units) 7-Aug-07 UN34_00249 RCV: Support/Mover Lot 7 (2 units) 28-Aug-07 Schedule

Procurement Philosophy The same procurement philosophy that was used so successfully for the strongbacks, magnets, poles, and undulator assembly will be applied here. Bid packages sent only to prequalified vendors Strong SOW including QA, delivery, and inspection requirements Clear assembly drawings Any procedures particular to this system are clearly detailed

Quadrupole magnets 1.04.03.05.01 Awarded to Everson-Tesla in September 2006 Issue of hysteresis-related motion of the magnetic center is being investigated together with the vendor; we are on a tight timeline but a decision on iron will be made soon.

Summary Undulator production progressing very well Support and Motion System passed its FDR and we are madly preparing for the RFQ. Quadrupoles are awarded. Working toward a rapid determination on the steel.

Just keep swimming