1 Assembly and installation of TM0 Lab components Assembly and installation of TM0 Lab components F. Rossi January 9th, 2012

2 Assembly and installation of TM0 Lab components INTRODUCTION This report is intended to give important updates concerning the current assembly procedure of TM0 Lab components. At the same time, the aim of this work is to provide to the engineering design useful feedbacks, coming from the recent field experience, to be taken into account for the next mechanical designs. Finally, possible modifications to the present design are discussed in detail, in order to improve and speed up the current assembly procedure.

3 Assembly and installation of TM0 Lab components 1.Drive beam 2.Main beam 3.Other components 4.Conclusions

4 Assembly and installation of TM0 Lab components DB: PETS unit Vacuum flange with adapter Damped bars Tank (short) Coupler middle mm mm  202 mm Coupler extremity Frictional contact Frictional contact EBW Tank

5 Assembly and installation of TM0 Lab components DB: assembly procedure steps (1) MACHINING & DELIVERY (1) MACHINING & DELIVERY (3) CLEANING 1.Passivation (copper)Passivation (copper) 2.Nickel coating (inox)Nickel coating (inox) 3.Degasing (SiC)Degasing (SiC) (3) CLEANING 1.Passivation (copper)Passivation (copper) 2.Nickel coating (inox)Nickel coating (inox) 3.Degasing (SiC)Degasing (SiC) (8) TIG WELDING 1.Fixed UHV flange + minitank tube (short)Fixed UHV flange + minitank tube (short) 2.Fixed UHV flange + minitank tubeFixed UHV flange + minitank tube (8) TIG WELDING 1.Fixed UHV flange + minitank tube (short)Fixed UHV flange + minitank tube (short) 2.Fixed UHV flange + minitank tubeFixed UHV flange + minitank tube (6) MACHINING 1.Coupler with on-off (x2)Coupler with on-off (x2) (6) MACHINING 1.Coupler with on-off (x2)Coupler with on-off (x2) (9) VACUUM BRAZING (PalCuSil 5, 820 °C) 1.Coupler extremityCoupler extremity 2.Coupler middleCoupler middle (9) VACUUM BRAZING (PalCuSil 5, 820 °C) 1.Coupler extremityCoupler extremity 2.Coupler middleCoupler middle (11) EBW 1.PETS unitPETS unit (11) EBW 1.PETS unitPETS unit (13) INSTALLATION ON GIRDERS (13) INSTALLATION ON GIRDERS (12) QUALITY CONTROL 1.Vacuum testVacuum test 2.Dimensional control on CMMDimensional control on CMM (12) QUALITY CONTROL 1.Vacuum testVacuum test 2.Dimensional control on CMMDimensional control on CMM (4) VACUUM BRAZING (PalCuSil 10, 880 °C) 1.2 minitank rings + minitank tube (short)2 minitank rings + minitank tube (short) 2.2 minitank rings + minitank tube2 minitank rings + minitank tube 3.Chamber for on-off mechanism (x2)Chamber for on-off mechanism (x2) 4.Coupler with on-off half 1 + half 2 (x2)Coupler with on-off half 1 + half 2 (x2) 5.Adapter disk 3 + DN rotat. flange (insert )Adapter disk 3 + DN rotat. flange (insert ) (4) VACUUM BRAZING (PalCuSil 10, 880 °C) 1.2 minitank rings + minitank tube (short)2 minitank rings + minitank tube (short) 2.2 minitank rings + minitank tube2 minitank rings + minitank tube 3.Chamber for on-off mechanism (x2)Chamber for on-off mechanism (x2) 4.Coupler with on-off half 1 + half 2 (x2)Coupler with on-off half 1 + half 2 (x2) 5.Adapter disk 3 + DN rotat. flange (insert )Adapter disk 3 + DN rotat. flange (insert ) (2) QUALITY CONTROL 1.Inlet inspectionInlet inspection 2.Dimensional controlDimensional control (2) QUALITY CONTROL 1.Inlet inspectionInlet inspection 2.Dimensional controlDimensional control (10) QUALITY CONTROL 1.Vacuum testVacuum test 2.Cooling circuit testCooling circuit test 3.FiducialisationFiducialisation (10) QUALITY CONTROL 1.Vacuum testVacuum test 2.Cooling circuit testCooling circuit test 3.FiducialisationFiducialisation (7) CLEANING 1.Coupler with on-off (x2)Coupler with on-off (x2) (7) CLEANING 1.Coupler with on-off (x2)Coupler with on-off (x2) (5) QUALITY CONTROL 1.Cooling circuit testCooling circuit test (5) QUALITY CONTROL 1.Cooling circuit testCooling circuit test

6 Assembly and installation of TM0 Lab components DB: PETS unit workflow 4. VACUUM BRAZING (PalCuSil 10, 880 °C) 4. VACUUM BRAZING (PalCuSil 10, 880 °C) 7. CLEANING (Passivation) 7. CLEANING (Passivation) 9. VACUUM BRAZING (PalCuSil 5, 820 °C) 9. VACUUM BRAZING (PalCuSil 5, 820 °C) 6. MACHINING 11. EBW 3. CLEANING 12. QUALITY CONTROL 10. QUALITY CONTROL QUALIITY CONTROL Cooling circuit test 1.Vacuum test 2.Fiducialisation 1.Vacuum test 2.Fiducialisation 1.Vacuum test 2.Fiducialisation 1.Vacuum test 2.Fiducialisation Fiducialisation Vacuum test 8. TIG WELDING Vacuum test 1.Vacuum test 2.Dimensional control (CMM Leitz) 1.Vacuum test 2.Dimensional control (CMM Leitz) 2. QC (Dimensional control) 2. QC (Dimensional control) Passivation (Cu), Nickel coating (Inox), Degasing (SiC)

7 Assembly and installation of TM0 Lab components DB: 2. Quality control Dimensional control of octants (CLIATLPE0002) manufactured by Costa (EDMS n ) and Inflite (EDMS n ) MANUFACTURER#  23 CIRCUMFERENCE [mm]  90 CIRCUMFERENCE [mm] COAXIALITY [mm] Theoretical Measured Theoretical Measured Theoretical Measured LeftRightLeftRightLeftRight Costa Inflite

8 Assembly and installation of TM0 Lab components DB: 3. Cleaning Cleaning procedure for brazing with PalCuSil (Palladium-Copper-Silver alloy): Copper parts: 1.Degreasing 2.Deoxidation 3.Passivation Stainless steel parts: 1.Nickel coating (not necessary if gold-copper alloy is used) DegreasingDeoxidation PassivationRinsing In addition: silicon carbide parts require a degasing cycle (2 hours at 1030 °C) before installation inside octants. Copper parts at the end of the cleaning procedure

9 Assembly and installation of TM0 Lab components DB: 4. Brazing BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 10 Max temperature: 880 °C BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 10 Max temperature: 880 °C Coupler with on-off Chamber for on-off mechanismMinitankVacuum flange with adapter Insertion of brazing alloy2 halves ready for brazing Brazed coupler

10 Assembly and installation of TM0 Lab components DB: 6. Machining The seat is machined with reference to the real dimensions measured on brazed chambers The flange seat is machined with reference to the real dimensions measured on RF flanges MACHINING OF INTERMEDIATE ADAPTER RINGS (after the 1st brazing step the clearance between cooling circuit adapters and coupler holes is too big for the 2nd brazing step) MACHINING OF NEW PLUGS (after the 1st brazing step the clearance between original plugs and coupler holes is too big for the 2nd brazing step)

11 Assembly and installation of TM0 Lab components DB: 9. Brazing BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 5 Max temperature: 820 °C BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 5 Max temperature: 820 °C

12 Assembly and installation of TM0 Lab components DB: 10. Quality control (fiducialisation - EDMS n ) DIMENSIONTHEORETICAL [mm] MEASURED [mm] (form error in brackets) PETS1PETS2  (0.135) / (0.017) (0.059) / (0.014) Flatness   (0.006)/ (0.015) (0.004) / (0.018)  (0.065) (0.048) Concentricity   (0.018) (0.005) Concentricity  Flatness  DIMENSIONTHEORETICAL [mm] MEASURED [mm] (form error in brackets) PETS1PETS2  120 (adapter disk) (0.039) / (0.074) (0.0439) / (0.099)  120 (support) (0.006) / (0.006) (0.006) / (0.006) Concentricity  120 (sup.) / /  (0.007) / (0.013) (0.001) / (0.008) (0.004) / (0.006) (0.004) / (0.009)  (0.075) (0.090)  (0.013) (0.011) Flatness  DIMENSIONTHEORETICAL [mm] MEASURED [mm] (form error in brackets) PETS1PETS2  120 (adapter disk) (0.031) / (0.053) (0.036) / (0.103) (0.034) / (0.101) (0.021) / (0.059)  120 (support) (0.007) / (0.007) (0.006) / (0.007) Concentricity  120 (sup.) / /  (0.006) / (0.007) (0.009) / (0.004) (0.008) / (0.006) (0.003) / (0.004)  (0.034) / (0.070) (0.045) / (0.084)  (0.013) / (0.012) (0.015) / (0.004) Flatness  / / FIDUCIALS

13 Assembly and installation of TM0 Lab components DB: 10. Quality control (fiducialisation - EDMS n ) Flatness after brazing: mm Form error of the external diameter after brazing: mm The different thermal expansions of the two materials (copper: = µm/m·K, satinless steel = µm/m·K in the temperature range °C) should be taken into account in order to reduce the residual deformations at the end of the heating process. In particular, the most critical phase is when the two materials cool down (with different coefficients of thermal expansion) once they are brazed (locked) together.

14 Assembly and installation of TM0 Lab components DB: 11. EBW 1. Installation on EBW tooling2. Assembly of PETS unit 3. Final assembly of EBW tooling 4. Preliminary alignment control 5. Final configuration 6. Alignment control using Romer arm 7. Transportation to EBW machine 8. PETS unit ready for EBW

15 Assembly and installation of TM0 Lab components DB: 11. EBW 9. PETS unit in horizontal position 10. Lifting 11. Installation on EBW machine12. PETS unit ready for tack welding 13. Tack welding14. Alignment control after tack welding 15. PETS unit ready for EBW 16. EBW 17. Vacuum test 18. Final alignment control

16 Assembly and installation of TM0 Lab components DB: 11. EBW (alignment control - EDMS n ) #DATEMEASURED ALIGNMENT ERRORCOMMENT 17/11/201196After 1st assembly on EBW tooling 210/11/ After disassembly and 2nd assembly on EBW tooling 311/11/ After tack welding and transportation 414/11/ After EBW PETS2 #DATEMEASURED ALIGNMENT ERRORCOMMENT 117/11/ After 1st assembly on EBW tooling 220/11/ After EBW PETS1 Alignment measurements after tack welding and transportation have not been repeated for the second PETS unit (PETS1), since no modifications have been found after transportation of the first one (PETS2). PETS2 PETS1 OCTANT (Costa #1) OCTANT (Costa #2) OCTANT (Costa #4) OCTANT (Costa #3) Octant with damping material

17 Assembly and installation of TM0 Lab components DB: 11. EBW Colour change of stainless steel parts due to the vaporization (and consequent deposition) of copper during EBW. To be taken into account for the future to prevent undesired copper depositions.

18 Assembly and installation of TM0 Lab components DB: 12. Quality control (dimensional control - EDMS n ) DIMENSIONTHEORETICAL [mm] MEASURED [mm] PETS1PETS2 Centre distance between RF flanges Centre distance between vacuum flanges

19 Assembly and installation of TM0 Lab components DB: 12. Quality control (dimensional control - data elaboration) Data from dimensional control can be elaborated to represent and visualise alignment errors between adjacent parts Exaggerated representation

20 Assembly and installation of TM0 Lab components DB: 13. Installation on girders 1. Installation on girders 2. Assembly of cooling circuits and clamps 3. Final configuration PETS2 PETS1

21 Assembly and installation of TM0 Lab components 1.Drive beam 2.Main beam 3.Other components 4.Conclusions

22 Assembly and installation of TM0 Lab components (1) MACHINING & DELIVERY (1) MACHINING & DELIVERY (2) QUALITY CONTROL 1.Inlet inspectionInlet inspection 2.Dimensional controlDimensional control (2) QUALITY CONTROL 1.Inlet inspectionInlet inspection 2.Dimensional controlDimensional control (3) CLEANING 1.Passivation (copper)Passivation (copper) 2.Nickel coating (inox)Nickel coating (inox) 3.Degasing (SiC)Degasing (SiC) (3) CLEANING 1.Passivation (copper)Passivation (copper) 2.Nickel coating (inox)Nickel coating (inox) 3.Degasing (SiC)Degasing (SiC) (4) VACUUM BRAZING (PalCuSil 10, 880 °C) 1.WFM WG cover + WFM WG body (x32=4x8)WFM WG cover + WFM WG body (x32=4x8) 2.Waveguide damping interface half 1 + half 2 (x32=4x8)Waveguide damping interface half 1 + half 2 (x32=4x8) 3.Stack type 1 (x6)Stack type 1 (x6) 4.Stack type 2 (x1)Stack type 2 (x1) 5.Stack type 3 (x1)Stack type 3 (x1) 6.Manifold cover (tank int.) + vacuum tube P1 (x8)Manifold cover (tank int.) + vacuum tube P1 (x8) 7.Manifold small cover 3 + small cover 3 insert (x32=4x8)Manifold small cover 3 + small cover 3 insert (x32=4x8) (4) VACUUM BRAZING (PalCuSil 10, 880 °C) 1.WFM WG cover + WFM WG body (x32=4x8)WFM WG cover + WFM WG body (x32=4x8) 2.Waveguide damping interface half 1 + half 2 (x32=4x8)Waveguide damping interface half 1 + half 2 (x32=4x8) 3.Stack type 1 (x6)Stack type 1 (x6) 4.Stack type 2 (x1)Stack type 2 (x1) 5.Stack type 3 (x1)Stack type 3 (x1) 6.Manifold cover (tank int.) + vacuum tube P1 (x8)Manifold cover (tank int.) + vacuum tube P1 (x8) 7.Manifold small cover 3 + small cover 3 insert (x32=4x8)Manifold small cover 3 + small cover 3 insert (x32=4x8) (5) QUALITY CONTROL 1.Cooling circuit test (disks stacks)Cooling circuit test (disks stacks) (5) QUALITY CONTROL 1.Cooling circuit test (disks stacks)Cooling circuit test (disks stacks) (8) VACUUM BRAZING (PalCuSil 10, 880 °C) 1.Manifold (hor) assembly (x8=1x8)Manifold (hor) assembly (x8=1x8) 2.Hor. manifold (mirrored) assembly (x8=1x8)Hor. manifold (mirrored) assembly (x8=1x8) 3.Vert. manifold assembly (x16=8x2)Vert. manifold assembly (x16=8x2) (8) VACUUM BRAZING (PalCuSil 10, 880 °C) 1.Manifold (hor) assembly (x8=1x8)Manifold (hor) assembly (x8=1x8) 2.Hor. manifold (mirrored) assembly (x8=1x8)Hor. manifold (mirrored) assembly (x8=1x8) 3.Vert. manifold assembly (x16=8x2)Vert. manifold assembly (x16=8x2) (12) VACUUM BRAZING (PalCuSil 5, 820 °C) 1.Structure type 1 (x6)Structure type 1 (x6) 2.Structure type 2 (x1)Structure type 2 (x1) 3.Structure type 3 (x1)Structure type 3 (x1) (12) VACUUM BRAZING (PalCuSil 5, 820 °C) 1.Structure type 1 (x6)Structure type 1 (x6) 2.Structure type 2 (x1)Structure type 2 (x1) 3.Structure type 3 (x1)Structure type 3 (x1) (14) QUALITY CONTROL 1.Vacuum testVacuum test (14) QUALITY CONTROL 1.Vacuum testVacuum test (15) VACUUM BRAZING (PalCuSil 5, 820 °C) 1.2 super AS for stack 12 super AS for stack super AS for stack 22 super AS for stack 2 (15) VACUUM BRAZING (PalCuSil 5, 820 °C) 1.2 super AS for stack 12 super AS for stack super AS for stack 22 super AS for stack 2 (18) EBW 1.MB assemblyMB assembly (18) EBW 1.MB assemblyMB assembly (21) INSTALLATION ON GIRDERS (21) INSTALLATION ON GIRDERS (17) QUALITY CONTROL 1.Vacuum testVacuum test 2.Cooling circuit testCooling circuit test 3.FiducialisationFiducialisation (17) QUALITY CONTROL 1.Vacuum testVacuum test 2.Cooling circuit testCooling circuit test 3.FiducialisationFiducialisation (20) QUALITY CONTROL 1.Vacuum testVacuum test (20) QUALITY CONTROL 1.Vacuum testVacuum test MB: assembly procedure steps (10) MACHINING 1.Manifold (hor) assembly (x8=1x8)Manifold (hor) assembly (x8=1x8) 2.Hor. manifold (mirrored) assembly (x8=1x8)Hor. manifold (mirrored) assembly (x8=1x8) 3.Vert. manifold assembly (x16=8x2)Vert. manifold assembly (x16=8x2) (10) MACHINING 1.Manifold (hor) assembly (x8=1x8)Manifold (hor) assembly (x8=1x8) 2.Hor. manifold (mirrored) assembly (x8=1x8)Hor. manifold (mirrored) assembly (x8=1x8) 3.Vert. manifold assembly (x16=8x2)Vert. manifold assembly (x16=8x2) (11) VACUUM BRAZING (PalCuSil 5, 820 °C) 1.Structure type 1 (x6)Structure type 1 (x6) 2.Structure type 2 (x1)Structure type 2 (x1) 3.Structure type 3 (x1)Structure type 3 (x1) (11) VACUUM BRAZING (PalCuSil 5, 820 °C) 1.Structure type 1 (x6)Structure type 1 (x6) 2.Structure type 2 (x1)Structure type 2 (x1) 3.Structure type 3 (x1)Structure type 3 (x1) (13) EBW 1.Small covers with SiCSmall covers with SiC (13) EBW 1.Small covers with SiCSmall covers with SiC (16) VACUUM BRAZING (PalCuSil 5, 820 °C) 1.Brazed stack 1Brazed stack 1 2.Brazed stack 2Brazed stack 2 (16) VACUUM BRAZING (PalCuSil 5, 820 °C) 1.Brazed stack 1Brazed stack 1 2.Brazed stack 2Brazed stack 2 (19) TIG WELDING 1.Vacuum flanges (x8)Vacuum flanges (x8) (19) TIG WELDING 1.Vacuum flanges (x8)Vacuum flanges (x8) (6) MACHINING 1.WFM WG brazed (x32=4x8)WFM WG brazed (x32=4x8) 2.WG damping interface (x32=4x8)WG damping interface (x32=4x8) 3.Stack type 1 (x6)Stack type 1 (x6) 4.Stack type 2 (x1)Stack type 2 (x1) 5.Stack type 3 (x1)Stack type 3 (x1) (6) MACHINING 1.WFM WG brazed (x32=4x8)WFM WG brazed (x32=4x8) 2.WG damping interface (x32=4x8)WG damping interface (x32=4x8) 3.Stack type 1 (x6)Stack type 1 (x6) 4.Stack type 2 (x1)Stack type 2 (x1) 5.Stack type 3 (x1)Stack type 3 (x1) (9) VACUUM BRAZING (PalCuSil 10, 880 °C) 1.Manifold (hor) assembly (x8=1x8)Manifold (hor) assembly (x8=1x8) 2.Hor. manifold (mirrored) assembly (x8=1x8)Hor. manifold (mirrored) assembly (x8=1x8) 3.Vert. manifold assembly (x16=8x2)Vert. manifold assembly (x16=8x2) (9) VACUUM BRAZING (PalCuSil 10, 880 °C) 1.Manifold (hor) assembly (x8=1x8)Manifold (hor) assembly (x8=1x8) 2.Hor. manifold (mirrored) assembly (x8=1x8)Hor. manifold (mirrored) assembly (x8=1x8) 3.Vert. manifold assembly (x16=8x2)Vert. manifold assembly (x16=8x2) (7) CLEANING 1.PassivationPassivation (7) CLEANING 1.PassivationPassivation

23 Assembly and installation of TM0 Lab components MB: workflow (stack 1) 4. VACUUM BRAZING (PalCuSil 10, 880 °C) 4. VACUUM BRAZING (PalCuSil 10, 880 °C) 7. CLEANING (Passivation) 7. CLEANING (Passivation) 8. VACUUM BRAZING (PalCuSil 10, 880 °C) 8. VACUUM BRAZING (PalCuSil 10, 880 °C) 6. MACHINING 13. EBW 3. CLEANING 9. VACUUM BRAZING (PalCuSil 10, 880 °C) 9. VACUUM BRAZING (PalCuSil 10, 880 °C) 11. VACUUM BRAZING (PalCuSil 5, 820 °C) 11. VACUUM BRAZING (PalCuSil 5, 820 °C) 12. VACUUM BRAZING (PalCuSil 5, 820 °C) 12. VACUUM BRAZING (PalCuSil 5, 820 °C) QC (Cooling circuit test) 5. QC (Cooling circuit test) Vacuum test 14. QUALITY CONTROL TYPE MACHINING Passivation (Cu), Nickel coating (Inox), Degasing (SiC)

24 Assembly and installation of TM0 Lab components MB: workflow (stack 2) 4. VACUUM BRAZING (PalCuSil 10, 880 °C) 4. VACUUM BRAZING (PalCuSil 10, 880 °C) 7. CLEANING (Passivation) 7. CLEANING (Passivation) 8. VACUUM BRAZING (PalCuSil 10, 880 °C) 8. VACUUM BRAZING (PalCuSil 10, 880 °C) 6. MACHINING 13. EBW 3. CLEANING 9. VACUUM BRAZING (PalCuSil 10, 880 °C) 9. VACUUM BRAZING (PalCuSil 10, 880 °C) 11. VACUUM BRAZING (PalCuSil 5, 820 °C) 11. VACUUM BRAZING (PalCuSil 5, 820 °C) 12. VACUUM BRAZING (PalCuSil 5, 820 °C) 12. VACUUM BRAZING (PalCuSil 5, 820 °C) QC (Cooling circuit test) 5. QC (Cooling circuit test) Vacuum test 14. QUALITY CONTROL TYPE MACHINING Passivation (Cu), Nickel coating (Inox), Degasing (SiC)

25 Assembly and installation of TM0 Lab components MB: workflow (stack 1 + stack2) VACUUM BRAZING (PalCuSil 5, 820 °C) 15. VACUUM BRAZING (PalCuSil 5, 820 °C) 16. VACUUM BRAZING (PalCuSil 5, 820 °C) 16. VACUUM BRAZING (PalCuSil 5, 820 °C) 18. EBW 19. TIG WELDING 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 17. QUALITY CONTROL TYPE 2 TYPE 1 TYPE 3 TYPE 1 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 20. QUALITY CONTROL Vacuum test STACK 1 STACK 2

26 Assembly and installation of TM0 Lab components MB: Step 1. Machining & Delivery The RF flange seat to be machined is very close to the bent zone (the cross-sectional area in that area is affected by the plastic deformation process). This result in a non-uniform distribution of material around the machined seat. This problem could be solved moving the area to be machined away from the plastic deformation zone (for example increasing the length of the extrusion). For every design, the requested clearance for brazing is: mm. Hor. manifold waveguide type 1 (CLIATLAS0097) & type 1 (mirrored) (CLIATLAS0120)

27 Assembly and installation of TM0 Lab components MB: Step 2. Quality control Dimensional control of roughness and flatness of a random disk (EDMS n ) CLIATLAS0105RoughnessFlatness Measured: Ra = 115 nm Prescribed: Ra = 400 nm Measured: = 0.01 mm Prescribed: = 0.01 mm

28 Assembly and installation of TM0 Lab components MB: Step 3. Cleaning Cleaning procedure for brazing with PalCuSil (Palladium-Copper-Silver alloy): Copper parts: 1.Degreasing 2.Deoxidation 3.Passivation Stainless steel parts: 1.Nickel coating (not necessary if gold-copper alloy is used) Deoxidation PassivationRinsing Copper parts at the end of the cleaning procedure In addition: silicon carbide parts require a degasing cycle (2 hours at 1030 °C) before installation inside manifolds. Degreasing

29 Assembly and installation of TM0 Lab components MB: Step 4. Brazing (WFM & WG damp. interf.) WFM WG damping interface BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 10 Max temperature: 880 °C BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 10 Max temperature: 880 °C

30 Assembly and installation of TM0 Lab components MB: Step 4. Brazing (disk stack) Assembly of disk stack using the v-shape column Circumferential alignment of disks using reference block Fixation system for transportation Transportation Transportation inside furnaceDisk stack ready to be brazed Insertion of brazing alloy inside grooves Reference block for circumferential alignment

31 Assembly and installation of TM0 Lab components MB: Step 4. Brazing (disk stack) Alignment measurements before and after brazing: before brazing: 11 µm after brazing: 34 µm The measurements before and after brazing are almost the same for the other disk stacks. Before brazing After brazing

32 Assembly and installation of TM0 Lab components MB: Step 6. Machining (disk stack) Machining of: 1.Cooling adapters seats 2.Flat surfaces in contact with manifolds (to improve flatness for the next brazing step) 3.Grooves for brazing alloy (specifications are given in the next slide) 4.Contact surfaces between consecutive disk stacks to improve total alignment of different stacks (picture on the right) 5.Corner surface (picture on the left) Disk stack configuration after brazing (exaggerated)

33 Assembly and installation of TM0 Lab components MB: Step 6. Machining (disk stack) Machining of grooves for insertion of brazing alloy

34 Assembly and installation of TM0 Lab components MB: Step 6. Machining (WFM & WG damp. interf.) An additional machining step after brazing is required for WFM and WG damping interface components, in order to improve the flatness of surfaces to be brazed with disk stack. WFM WG damping interface Special indications are required for those asymmetrical parts where the asymmetry might not be so evident during the assembly procedure. Configuration after brazing (exaggerated)

35 Assembly and installation of TM0 Lab components BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 10 Max temperature: 880 °C BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 10 Max temperature: 880 °C MB: Step 8. Brazing (manifolds) Manifolds are brazed in two steps to improve the stability of the assembly inside the furnace (the lower waveguides are brazed in the next step). The alignment is performed using the reference column.

36 Assembly and installation of TM0 Lab components MB: Step 9. Brazing (manifolds) Long and short waveguides are brazed during this step, as well as the last two WG damping interfaces. BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 10 Max temperature: 880 °C BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 10 Max temperature: 880 °C

37 Assembly and installation of TM0 Lab components MB: Step 10. Machining (manifolds) After brazing, steps are present on the lateral surfaces of manifolds. The presence of these steps makes difficult the insertion of manifolds inside disk stack. These steps are removed by an additional machining of the lateral surfaces (in green). Manifold configuration after brazing (exaggerated) Steps Areas to be machined on the lateral surfaces of manifolds The frontal surface (in red) is machined as well to improve the contact with the surface of disk stack.

38 Assembly and installation of TM0 Lab components MB: Step 11. Brazing (disk stack + manifolds) EBW of covers is not feasible, since manifolds are brazed (the heat generated by EBW process would melt the brazing material between consecutive manifold cells). Therefore covers have to be brazed with SiC inside manifolds. Experimental tests confirmed the feasibility (the biggest doubts were related to the different thermal expansions of copper and SiC). During this brazing step, the following parts are brazed together: o 1 disk stack o 2 manifolds with waveguides o 1 simple cover o 1 cover with adapter tube for vacuum flange o SiC are inserted inside manifolds (only for stack 1, since SiC are not present in stack 2) Disk stack Manifold with waveguide Simple cover Damping material Cover with adapter tube BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 5 Max temperature: 820 °C BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 5 Max temperature: 820 °C

39 Assembly and installation of TM0 Lab components BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 5 Max temperature: 820 °C BRAZING PARAMETERS Atmosphere: vacuum (10 -5 mbar) Brazing alloy: PalCuSil 5 Max temperature: 820 °C MB: Step 12. Brazing (disk stack + manifolds) During this brazing step, the last two manifolds are brazed to the disk stack. More in detail, the parts to be brazed are: o 2 manifolds with WG damping interface o 2 simple covers o 4 RF flanges o SiC are inserted inside manifolds (only for stack 1, since SiC are not present in stack 2) Manifold with WG damp. interf. Simple cover RF flange Damping material

40 Assembly and installation of TM0 Lab components MB: Step 13. EBW (small covers with SiC - stack 1) The clearance between small covers and corresponding seats (on WFM and WG damping interface) is too big for brazing. EBW tests are planned to EB weld the small covers. Nevertheless, even in this case, some critical issues are present: o the current clearance is bigger than the optimal one for EBW (0.05 mm) o brazing material is present around the area to be EB welded: it can melt due to the high temperatures involved in the process causing vacuum leaks. If the vacuum test is not successful after EBW, an additional brazing step will try to eliminate the presence of leaks. In CLIATLAS0061 indium has been replaced by stainless steel pins (  1 x 6 mm). Clearance > 0.05 mm Presence of brazing material

41 Assembly and installation of TM0 Lab components MB: Step 13. EBW (stack 2) Since SiCs are not present in stack 2 of both TM0s, some modifications to the current design might simplify the assembly procedure. Covers could be integrated into manifolds so that step 11 and step 12 could be simplified, as well as step 13 could be cancelled. WFMWG damping interface Manifold standard cell

42 Assembly and installation of TM0 Lab components MB: Step Brazing Stack 1 (with SiC) and stack 2 (without SiC) are brazed in two different steps. During the first step, two accelerating structures are brazed together to realize one super-accelerating structure. In the second step, two super-accelerating structures are brazed together to realize a complete stack. During this step the following parts are brazed as well: o top vacuum flange with bellow (x1) o cooling circuit adapters (x32) o bottom intermediate piece (x1) The stack is not symmetric due to the position of RF flanges and waveguides, therefore the centre of mass is not on the axis of the structure (it is shifted ahead towards the RF flange). For this reason, an eccentric weight is applied to the top of the structure to increase the stability inside the furnace: the position and the value of the weight has been determined in a previous study made by R. Raatikainen. For the same reason the 4 lateral vacuum flanges are TIG welded at the end. The cooling circuit adapters are brazed during this step: in this way the alignment of the stack can be checked using the measuring column.

43 Assembly and installation of TM0 Lab components MB: Step 16. Brazing x y 8.47 mm 4.88 mm centre of mass PARTm [kg] G (x, y) [mm]M [kg·mm] xyMxMy Vacuum flange Adapter tube RF flange WG long WG short M x,tot = kg·mm (4 vacuum flanges) M y,tot = kg·mm (16 RF flanges + 8 WG long + 8 WG short) If we consider only the 4 RF flanges, the position (y W ) and the mass (m W ) of the eccentric weight to be used is given by: y W [mm]m W [kg] σ z = -1.8 MPa σ z = MPa Asymmetrical stress distribution due to the eccentric position of the centre of mass (vacuum flanges are not considered)

44 Assembly and installation of TM0 Lab components MB: Step 17. Fiducialisation Since the assembly procedure has been modified, some modifications are required even for the fiducialisation procedure. Three different options are presented in the next slides and resumed hereafter: o Option 1: it is the first solution proposed several months ago, but that cannot be taken into account anymore due to the modifications imposed to the current assembly procedure. o Option 2: it is a second solution designed according to the guidelines given for option 1. Its main disadvantage is the required time (*). o Option 3: it is a solution that allows to obtain the same results of the previous methods, but saving a lot of time (*). (*) the forecasts are based on the time spent for PETS fiducialisation

45 Assembly and installation of TM0 Lab components MB: Step 17. Fiducialisation (option 1) Stack 1 (with SiC) Fiducialisation of 4 AS using CMM Leitz Alignment control using Romer Arm Dimensional control using CMM Leitz Required time: 1 month (1 week for each AS) Required time: 1 week Advantages: Alignment control before and after brazing Disadvantages: Total time (more than 2 months for 1 TM0) Fiducialisation might be lost after brazing (probably another one might be necessary) Brazing Ovalization of fiducials after several brazing steps

46 Assembly and installation of TM0 Lab components MB: Step 17. Fiducialisation (option 2) Stack 1 (with SiC) Brazing Fiducialisation of 4 AS using CMM Leitz Alignment control using Romer Arm Fiducialisation of 2 super- AS using CMM Leitz Alignment control using Romer Arm Dimensional control using CMM Leitz Required time: 1 month (1 week for each AS) Required time: 1 week Required time: 2 weeksRequired time: 1 week Advantages: Alignment control before and after brazing Disadvantages: Total time (more than 4 months for 1 TM0)

47 Assembly and installation of TM0 Lab components MB: Step 17. Fiducialisation (option 3) Stack 1 (with SiC) Brazing Alignment control using measuring column Fiducialisation using CMM Leitz Required time: 2 days Required time: 1 week Advantages: Alignment control before and after brazing Total time (3 weeks for 1 TM0) New fiducials can be glued on the stack since no other brazing steps are required (taking into account the presence of clamps on girders) Disadvantages: None Brazing Alignment control using measuring column

48 Assembly and installation of TM0 Lab components MB: Step 17. Fiducialisation 1. Received from Bodycote 2. Removal from box 3. Assembly of intermediate tooling 4. Intermediate tooling 5. Assembly of EBW tooling 6. Removal 7. Transportation to Metrology 8. Removal from box 9. Rotation 10. Transportation around Metrology 11. Assembly of lifting tooling (under design) and installation on CMM for fiducialisation

49 Assembly and installation of TM0 Lab components MB: Step 18. EBW 12. Removal from CMM machine 13. Assembly of EBW tooling and transportation to EBW area 14. EBW of 2 stacks (tooling under design) EBW tooling for welding 2 stacks is currently under design. As soon as the 3D model is completed, a meeting with EBW people will be organize to discuss the preliminary ideas and to modify it according to their suggestions. EBW

50 Assembly and installation of TM0 Lab components MB: Step 19. TIG welding 15. Transportation of welded stacks to TIG welding area 16. TIG welding of vacuum flanges (x8)

51 Assembly and installation of TM0 Lab components MB: Step 21. Installation on girders 17. Transportation to building Disassembly of EBW tooling and assembly of lifting tooling for installation on girders (under design) The alignment of manifolds is very important for the correct installation of MB on the v-shape supports. In particular, the alignment is very important in the following steps: step 15: brazing of super ASs for stack 1 and 2 step 16: brazing of stack 1 and stack 2 step 18: EBW of 2 stacks Step 15 Step 16 Step 18 Manifolds to be aligned

52 Assembly and installation of TM0 Lab components 1.Drive beam 2.Main beam 3.Other components 4.Conclusions

53 Assembly and installation of TM0 Lab components OTHER COMPONENTS: compact load 922 Compact loads are brazed in a single step instead of two as previously considered Quality controls: 1.Cooling circuit test 2.Vacuum test

54 Assembly and installation of TM0 Lab components OTHER COMPONENTS: RF network Pre-assembly of RF network

55 Assembly and installation of TM0 Lab components OTHER COMPONENTS: magnets New supporting plates with adjustment systems are necessary to improve the alignment of magnets

56 Assembly and installation of TM0 Lab components 1.Drive beam 2.Main beam 3.Other components 4.Conclusions

57 Assembly and installation of TM0 Lab components CONCLUDING REMARKS The cleaning step turned out to be a bottleneck for the assembly procedure due to the great number of pieces to be cleaned: the problem has been solved commissioning COMEB to do the cleaning of MB pieces. Concerning PETS, the theoretical tolerances prescribed for octants have not been fulfilled by both manufacturers (Costa and Inflite), in particular for what regards the required concentricity. Nevertheless, the manufacturing errors of the second company are lower than the first one. Gold-copper alloy has been replaced by PalCuSil alloy for vacuum brazing. The temperatures involved in the process are lower and different brazing steps using the same brazing alloy have been realised. Concerning the MB, 2 new machining steps and 3 additional brazing steps have been added to the initial assembly procedure. Moreover, modifications have been necessary in order to replace the EBW step for welding of covers. After brazing, an additional machining step should be always considered for all those mating surfaces that are involved in a following brazing step: deformations occur (very often) after each heating process, the aim of this machining step is to restore the optimal clearance for the next brazing.

58 Assembly and installation of TM0 Lab components FUTURE ACTIONS Finally, some little requests for the future: Specify the presence of alignment pins for brazing (in BOM) Indicate the weight of assemblies in 2D drawings Main actions: MB Modifications to manifolds design for stack 2 with no SiC (slide n. 41) in order to skip the EBW step for welding of small covers (step #13, slide n. 24) and speed up the assembly procedure. Meeting with EBW people in order to approve the 3D model of EBW tooling, complete the 2D drawings and start the procurement (people involved: F. Rossi, M. Imran, A. Samochkine, S. Lebet, S. Atieh, T. Tardy). Lifting tooling for dimensional control of 1 stack on CMM and installation on girders (M. Imran). Approval of the modifications to the fiducialisation procedure (F. Rossi, S. Griffet). MAGNETS New supporting plates to be designed and manufactured