1 Status of the CLIC two-beam module program A. Samochkine, G. Riddone Acknowledgements to the Module WG members 4 February 2014 CLIC Workshop 2014 (3-7 February 2014)

2 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» Content Introduction to module –TBM LAB –TBM CLEX Test program Module design, component fabrication and assembly –TBM LAB –TBM CLEX Conclusions

3 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM LAB. Overview Systems to test: Supporting & pre-alignment RF structures Vacuum Cooling MBQ stabilization No beam, thermo-mechanical tests 3 modules in series (final configuration “0 - 1 – 0”) Real mechanical interfaces, quasi-nominal assembly procedure Functional RF mock-ups

4 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM CLEX. Overview TBM CLEX One TBMPriming RF Network Integration in CLEX TBM RF and beam 1 module + existing PETS Real RF structures

5 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM Test Program CLEX Demonstration of the two-beam acceleration with fully fledged two- beam module Address feasibility issues in an integrated approach (detailed program under finalization) Demonstration of the two-beam acceleration with fully fledged two- beam module Address feasibility issues in an integrated approach (detailed program under finalization) LAB Validation of different types of girders and movers Pre-alignment of girders/quadrupoles in the module environment Validation of interconnections and vacuum system under different thermal loads Measurement of resonant frequencies Simulation of several thermal cycles and alignment verification Transport of the module and alignment verification Validation of different types of girders and movers Pre-alignment of girders/quadrupoles in the module environment Validation of interconnections and vacuum system under different thermal loads Measurement of resonant frequencies Simulation of several thermal cycles and alignment verification Transport of the module and alignment verification

6 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» Supporting/ pre-alignment RF Components Vacuum system Cooling system TBM LAB T0#1. Overview Considering the module consisting of several “layers”:

7 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM LAB Main Beam. Accelerating Structures  Overall length  2010 mm  Simplified parts = reduced cost  Mechanical interfaces are equal to real AS  Internal surface area is equal to real AS  Cooling system is equal to real AS VACUUM MANIFOLD ( x 32 ) DISK STACK ( x 8 ) COOLING SYSTEM CONNECTOR ( x 64 ) COMPACT LOAD INTERFACE ( x 16 ) INTERMODULE INTERCONNECTION ( x 2 ) AS – VAC. TANK INTERCONNECTION ( x 8 ) WAKE FIELD MONITOR ( x 32 ) RF NETWORK INTERFACE ( x 16 ) See talk “Experience assembling structures with damping manifolds” on Wed ’14

8 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM LAB Main Beam. Accelerating Structures

9 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM LAB Main Beam. Accelerating Structures Standard fittings: Cu tubes Brazing of 2 stacks 1005 mm + Interconnections MB-MB; Welding (EBW) of two stacks together x 2 x 1 EBW

10 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM LAB Drive Beam. PETS mock-up Octants replaced by simplified single body bar Simplified damping inserts On-Off actuator is replaced by the plug The inner geometry is simplified Using of interconnection flanges Using of screw cooling fittings PETS MOCK-UP INTERCONNECTION PETS MINITANK PETS ON-OFF (COUPLERS) DAMPING INSERT

11 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM LAB Drive Beam. PETS mock-up General assembly. EB welding. CC subassemblies. Brazing. Compact Coupler subassemblies. Brazing. Minitank. Brazing & Welding. Mock-up Compact Coupler. Brazing. EBW

12 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM LAB PETS mock-up, EBW Final assembly step. Electron beam welding accomplished by CERN main workshop.

13 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM LAB RF network The RF network (incl. hybrid, splitter and CMF) is meant to transfer the RF power from PETS (Drive Beam) to accelerating structures (Main Beam). SPLITTER HYBRID FROM PETS TO AS CHOKE MODE FLANGE COOLING PIPE REINFORCEMENT TO LOAD standard WR90 profiles the inner geometry of machined parts is simplified using of interconnection RF flanges The assembly procedure is similar to one for real component

14 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM LAB RF network Hybrid (also splitters and elbows). Brazing. Splitter sub-assy. Brazing. CMF sub-assy. Brazing. General assembly. Brazing. Cooling pipe. Brazing. Reinforcement. Low temp. brazing.

15 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM LAB Vacuum Network Network connected rigidly to the vacuum tank Bellows used between compact loads and vacuum network PETS and AS connected to vacuum tank COLLECTOR TUBE Ø64 TUBES Ø28 BELLOWS COMPACT LOAD MOCK-UP TO VAC. TANK FROM AS MAIN BEAM

16 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM LAB Cooling System Nominal cooling system simulated to cool about 7.5 kW dissipated power 1.Insert tube 2.Tighten the nut Standard fitting are used to avoid brazing or welding operations:

17 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM LAB Experimental results SAS, example T AMB = 20 °C, V AIR = 0.4 m/s, V SAS = m 3 /h Heat power: 50% Heat power: 100% Surface temperature :  Average: 31.4 °C  Max: 32.1 °C Average water temperature increase per SAS: +6.3 °C Transient time from 50% to 100%: ~20 min. Measurements in agreement with expectation Surface temperature:  average: 28.0 °C  Max: 28.6 °C Average water temperature increase per SAS: +3 °C

18 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM CLEX. Integration Priming RF network specially developed for providing the RF power Fully equipped module (with supports) integrated in the CLEX line PB DB 2320 TWO-BEAM MODULE

19 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM CLEX Supporting System Validation of the positioning system before starting the assembly of the module (by SU colleagues) Installation of the motorized stations of the 1 st batch supporting systems at the supplier facility 1 st batch supporting systems (SiC) at the supplier facility Alignment measurements Delivered at CERN: currently under CMM, first measurements within the specification

20 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM CLEX DB BPM. Assembly Fabrication of all pieces under completion Feedthroughs under testing Installation of SiC rings (assembled with copper interface parts) inside the body; Welding of the drift tube; Welding of the bellows; Screwing of RF-fingers. CF FLANGE & BELLOWS ASSEMBLY RF-FINGER & SiC RING ASSEMBLY MAIN BODY ASSEMBLY DRIFT TUBE SIC RING & CU-INTERFACE ASSEMBLY RF-FINGER QCF FLANGE & BELLOWS ASSEMBLY FEEDTHROUGH

21 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM CLEX. PETS The production of the 2 nd PETS has been launched by CIEMAT: 8 x Octants production is finished; Assembly of 8 x Octants ready; Production of mini tank and couplers finished Electron beam welding is expected in the coming weeks (CERN); PETS RF check PETS before EBW PETS#1 finalized and successfully checked PETS#2 RF check before final welding OK

22 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» TBM CLEX. Several other components Few hundreds pieces needed for one module

23 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» Schedule

24 04-February-2014 CLIC Workshop 2014 «BE-RF-PM» Summary  Module program very important to understand technical issue on integrated approach  All the components of the TM0 #1 have been successfully manufactured and module assembled in the LAB 169. Module currently under test.  The important lessons learnt during the fabrication of the components and module assembly are taken into account for the next TBM prototypes, especially the experience on SAS mock fabrication was indispensable for the production of real structures for CLEX  Alignment system fully validated  Heating/cooling systems operating as expected  Final duty cycles and failure scenarios under completion (thermal behaviour and alignment of components)  TM0 #2 under fabrication and assembly  Module review on roadmap for TBM LAB in Nov 2013: TBM LAB: final configuration ‘0-1-0’ TBM CLEX: final configuration ‘0’  TBM CLEX under fabrication and assembly (installation from June 2014)