Type IV Cryomodule Proposal (T4CM) Don Mitchell, 16 JAN 2006

16 JAN 06D. Mitchell, FNAL2 Design Reference: TTF III+

16 JAN 06D. Mitchell, FNAL3 TTF III+ Cryomodule Courtesy of DESY

16 JAN 06D. Mitchell, FNAL4 ILC Cryo Design Considerations  Move quad package to middle of cryomodule to achieve better support and alignment.  Shorten cavity-to-cavity interconnect and simplify for ease of fabrication and cost reduction. Possible superconducting joint.  Overall improved packing factor.  Minimize direct heat load to cavity through MC.  Simplify the assembly procedure.  MLI redesign to reduce hands-on labor costs.  More robust design to survive shipping.  Reliability of tuner motors in cold operation.  Etc. (we’ve heard many suggestions)

16 JAN 06D. Mitchell, FNAL5 Increase diameter beyond X-FEL Increase diameter beyond X-FEL Review 2-phase pipe size and effect of slope

16 JAN 06D. Mitchell, FNAL6 T4CM Proposal (not the final ILC design)  Magnet alignment and vibration issues.  Cryomodule with and without magnet package Define BPM, Steering, and Quad parameters Possible option for separate magnet cryovessel  Reduced cavity length (which tuner design?)  Reduced cavity spacing (new interconnect)  Need for functional Fast-Tuner Current Cryo3 Minor changes to address major concerns.

16 JAN 06D. Mitchell, FNAL7 Conceptual Model Development

16 JAN 06D. Mitchell, FNAL8 Assumes use of XFEL Main Coupler Graphics from Terry Garvey

16 JAN 06D. Mitchell, FNAL9 Generation 4, T4CM

16 JAN 06D. Mitchell, FNAL10 Beware of a ripple effect! Design Changes

16 JAN 06D. Mitchell, FNAL11 Known Impacts Vessel weldment Linac Layout Main coupler position Magnetic shield design Integrated with supplier HGR pipe weldement cryogenic piping details Invar rod length including thermal shrinkage calculations Wire position monitor locations Waveguide connections Helium supply pipe lengths Design Change Example: Modified Cavity Length

16 JAN 06D. Mitchell, FNAL12 Potential Impacts Transportation fixtures Etching jackets EP process tooling High pressure rinse Process tooling Controls programming Design Change Example: Modified Cavity Length

16 JAN 06D. Mitchell, FNAL13 T4CM Proposed Cavity w/ Bladetuner

16 JAN 06D. Mitchell, FNAL14 Cavity Spacing 71.8 mm

16 JAN 06D. Mitchell, FNAL15 Cavity Dimensions

16 JAN 06D. Mitchell, FNAL16 Cryomodule – A working 3-D model

16 JAN 06D. Mitchell, FNAL17 Excel driven 3-D I-DEAS Model

16 JAN 06D. Mitchell, FNAL18 Multi-linked Excel Sheets drive 3-D CAD

16 JAN 06D. Mitchell, FNAL19 Excel usage integrates engineering calculations into the 3-D CAD process!

16 JAN 06D. Mitchell, FNAL20 Automatically adjusts for thermal contraction and component lengths

16 JAN 06D. Mitchell, FNAL mm mm mm

16 JAN 06D. Mitchell, FNAL22 Packing factor 35109mm mm Active length = mm x 24 cavities = mm Packing Factor = / = 0.71 Note: Does not include other components installed within the accelerator nor a possible increased magnet package length.

16 JAN 06D. Mitchell, FNAL23 No matter how simple the proposed changes are, this is no small task!  Concept development / Collaboration  Engineering analyses to appropriate standards  Part design  3-D modeling (concepts to reality)  ~750 parts / assembly drawings  Vendor integration  Procurement process  Fabrication  Assembly  Installation

16 JAN 06D. Mitchell, FNAL24 Design coordination sample worksheet

16 JAN 06D. Mitchell, FNAL25 Free 3-D Visualization with UGS JT2GO

16 JAN 06D. Mitchell, FNAL26 Proposed 4 th Generation Design  2 Vessels, ΔLength= mm (w & w/o Magnet package)  Cavity string supported and aligned by 3 support posts.  Magnet independently aligned but still supported from the 300mm HGR pipe. (HGR Pipe may need to be resized)  Support post locations may be identical in both vessels to simplify the tooling.  HOM absorber in interconnect region. What length?  Smaller cav-to-cav connection (71.8mm)  BPM, Quad magnet, and steering magnets are combined into one magnet package. Total length currently assumed to be 1222 mm. Should this length be increased to 1500mm?  TTF III cavity utilizes short end-tube for both ends. Length reduced to mm.  Possible use of Bladetuner due to the shortened cavity length.  New Magnetic Shield design is required.  All ports and flanges will be metric and ISO style.

16 JAN 06D. Mitchell, FNAL27 T4CM will differ from Type III+  Cavity iris-to-iris spacing reduced to 283 mm  String length changes from 12200mm to ~12565mm.  Slow tuner modified to allow closer cavity-to- cavity spacing (could mean switching to bladetuner design, but choice still open).  Fast tuner -- new design needed.  Quad/corrector/BPM package under center post, hung from 300 mm tube, not on rollers (diverging from X-FEL).  Two major module types, one with quad and one without.

16 JAN 06D. Mitchell, FNAL28 More differences of T4CM from Type III+  Interconnect features modified to accommodate an input coupler at end of cryostat as well as a new HOM absorber.  Quad current leads may be new, with local impact on thermal shields and vacuum vessel ports. May need large access ports as well.  Provisions for quad power lead connection at center of module.  Address magnet alignment issues.  Some pipe sizes will be increased for lower pressure drops with high flow rates -- would like to retain long cryogenic unit lengths up to limit of 300 mm pipe and cryo plants. Present effort includes re-analysis of heat loads, flow rates, and cryogenic system thermal process.

16 JAN 06D. Mitchell, FNAL29 Some critical open design issues  Quad/corrector/BPM package is a major unknown right now and goes into the heart of the module.  Tuner details, slow and fast, but especially fast tuner  Cavity-to-cavity interconnect design.  Vibrational analysis, which will be compared to measurements for verification of the model for future design work.  Magnetic shield re-design.  Development of module and module component tests.  Verification of cavity positional stability with thermal cycles.  Design of test instrumentation for the module.  Robustness for shipping, analysis of shipping restraints and loads, shipping specifications.  Active quad movers(?) A complication