LQ Reaction & Impregnation Tooling Internal Review F. Nobrega, N. Andreev August 13, 2007

Introduction This review is for the LQ reaction and impregnation tooling. – Tooling features – Reaction process – Impregnation process Reaction and impregnation tooling for LARP’s long quadrupole (LQ) is a blend of TQ reaction tooling and the long dipole mirror (LM) reaction tooling design experience. The 6 m LHC curing mold tooling will be used for LQ coils. LQ React/Impreg Review August 13, 2007 F. Nobrega, N. Andreev 2

Four long dipole coils have been fabricated, 2 x 2m & 2 x 4m. The 2m coil used in LM01 went to it’s short sample limit. The 4m coil is being prep’ed for potting. 3 2m coil prep for reaction 4m coil after curing L2 LQ React/Impreg Review August 13, 2007 F. Nobrega, N. Andreev

4 ۩ Reaction & impregnation tooling features: Mandrel is same design for both reaction and impregnation tooling assemblies. Coil to tooling alignment features exist in reaction and impregnation tooling. – Alignment can be maintained using pins throughout the coil reaction/impregnation fabrication process. LQ React/Impreg Review August 13, 2007 F. Nobrega, N. Andreev

5 ۩ Reaction & impregnation tooling features: Mandrel is asymmetrically keyed to the base plate. During reaction, the mandrel has 10 mil gaps for radial argon flow & two ¼” holes for longitudinal argon flow. 1.5mm steel spacer at parting plane Stainless steel 10 mil shell used on outer radius for both reaction and impregnation processes. LQ React/Impreg Review August 13, 2007 F. Nobrega, N. Andreev

6 ۩ Reaction & impregnation tooling features: O-rings between end plate & block/base plate. Longitudinal gaskets clamped into position with pushers & screws. Space between coil & end plates are 0.38: on LE & 0.88” on RE. End plates have argon inlet & exhaust features. LQ React/Impreg Review August 13, 2007 F. Nobrega, N. Andreev

7 ۩ Reaction Process  Remove cured coil from mold  Place in roll-over station & roll over 4m dipole coil being extracted from mold roll-over station 2m dipole coil LQ React/Impreg Review August 13, 2007 F. Nobrega, N. Andreev

8 ۩ Reaction Process  Coil and winding mandrel are placed on base plate.  Remove retainer and main pushers while screws hold arc pushers in place.  Poles are held in place by screws during curing & replaced with ¼” pins.  Add outer layer insulation and stainless steal shell. Remove most of the arc pushers. – Periodically along the length arc pushers held in place by a bar. (used to support coil in case of binder failure)  Complete assembly using main blocks, spacers between base plate and main blocks, alignment bars and assembly bolts.  Place in roll-over fixture & roll over. spacers Main blocks Base plate LQ React/Impreg Review August 13, 2007 F. Nobrega, N. Andreev

9 ۩ Reaction Process  Remove bolts and base plate.  Remove winding mandrel followed by arc pushers.  Install 1.5 mm mid-plane spacer and mandrel. Mandrel.007” above reaction block. TQ24 cured coil size.005” large at mid-plane. LQ React/Impreg Review August 13, 2007 F. Nobrega, N. Andreev

10 ۩ Reaction Process  Add top plate and bolt assembly.  Final step, prep and react. LQ React/Impreg Review August 13, 2007 F. Nobrega, N. Andreev

11 ۩ Impregnation Process  Remove alignment bars, blocks and shells.  Perform splice operation.  Remove outer radius heat treated insulation and install new installation, strip heaters and shells. Leads exposed for splice assembly LQ React/Impreg Review August 13, 2007 F. Nobrega, N. Andreev

12 ۩ Impregnation Process  Reassemble and roll over.  Remove base plate and mandrel.  Instrument as required, add ceramic to inner radius.  Install mandrel, base plate and bolt assembly.  Final step, prep and impregnate. 4m dipole coil in reaction impregnation fixture LQ React/Impreg Review August 13, 2007 F. Nobrega, N. Andreev

Summary LQ reaction and impregnation tooling is an iteration of TQ and LM tooling. Coil to coil alignment features exists. Coil to tooling alignment features exists. Design is compatible with existing tooling at Fermilab. 13 LQ React/Impreg Review August 13, 2007 F. Nobrega, N. Andreev