1 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Options for modifications to parts and procedures M. Anerella February 3, 2016 representing work by J. Schmalzle, P. Kovach ? “Se non è vero, è ben trovato”

2 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Goals 1.Improve quality 2.Reduce assembly labor costs / time 3.Reduce material costs

3 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures candidates 1.Improve closure procedure of reaction & impregnation fixtures 2.Build solid impregnation fixture formblocks 3.Improve coil instrumentation wire splice design 4.Utilize stamped lamination collars, pads, yokes 5.Provide additional space for tuning shims (in collars and/or pads) 6.Remove bolts from collars & pads 7.Eliminate masters 8.“tune” aluminum support shells to reduce coil stress variations along the axial direction 9.Utilize full length keys, bladders 10.Utilize extruded bladders 11.“four-fold” bladder pressurization

4 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Goal – maintain parallelism of fixture during bolting procedure Present (FNAL/CERN) method – bolt fixture halves to shim(s) first, then unbolt, remove shim(s) and perform final bolting —Additional bolting step takes extra time/cost for both R&I assemblies of every coil —Parallelism of final closure is still not guaranteed at final bolting 1. Improve impregnation fixture closure procedure Alternative → Bolt fixture using incremental torques applied simultaneously to both fixture sides & measure incremental gaps at each torque step to ensure parallelism gap

5 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures 2. Build solid impregnation formblocks Replace top plate and EDM blocks with solid formblocks, 4.2 m long (Q1/Q3) sections, machined & honed 0-ring seal to base plate Mandrel blocks remain unchanged (50 mm EDM) Simplified solid tool Liner is eliminated Side bars and screws are eliminated Pusher bars and screws are eliminated Top plate is eliminated * All changes improve tolerance and reduce cost * Mating surface is maintained to retain compatibility with reaction fixture plate Impact to present design Vendor quote for 4.6 m sst part is $114K each Can recycle existing fb’s for reaction fixtures Reduces cleaning, prep time w.r.t. EDM blocks Existing solid RHIC 10m coil tooling

6 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Simplified wiring procedure – G11 fillers with windows for making wire connections: Eliminates need to package short wires inside impregnation fixture. Eliminates need to extend short wires after impregnation 3. Improve coil instrumentation wire splice design (I) G11 Fillers Teflon Inserts Procedure before impregnation: Position trace in wiring pocket. Install G11 filler over trace. Install Teflon inserts in wiring windows.

7 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Wires soldered Procedure after impregnation: Remove Teflon inserts. Solder wires to trace. Fill windows with epoxy putty. → provides strain relief for solder connections Epoxy Putty. (tried also blue Stycast epoxy – more difficult to fill work with. Putty is easy to apply and smooth flush) 3. Improve coil instrumentation wire splice design (II)

8 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures 4. Utilize stamped lamination collars, pads, yokes 1.EDM parts are expensive & relatively hard to fabricate to required tolerances 2.Stamped laminations reduce cost, increase accuracy 3.EDM / solid parts can be used in select areas where needed (yoke fiducials, etc.) as outlined by CERN

9 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures No compromise to structural integrity, function; Collar – Pad loading surfaces unaffected Elimination of bolts (#6) provides significant opportunities for magnetic shimming in collars, pads Elimination of masters (#7) provides significant opportunity in deeper bladder slots in pads, yokes 5. Provide space for tuning shims (in collars/pads/yokes) Additional Magnetic Shimming iron = new / increased magnetic shim locations

10 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures 6. Remove bolts from collars & pads 1.Bolted collars are time consuming to assemble & result in an assembly that is difficult to maintain proper shape (see results presented at Structure Review; 10 mils smaller at bottom than at top) 2.Full length closure of keyed collars* prevents separation from coil key due to Lorentz forces, improves alignment * note: assumes “LARP-style” of assembly. 1.Bolted pads may be eliminated in conjunction with eliminating masters (see #7) Stamped aluminum collar laminations: Single part for all lams Critical features stamped Closure features machined on 1 surface Eliminates the need for accurate pinning or welding Tapered phosphor bronze collaring keys: 6 degree included angle (self locking) Easily installed by hand or light tapping, self locking ~ 1 mm shorter than keyway, allows ~ 0.2 mm adjustment in collar closure against coil key if needed Helium flows freely from holes in coil pole keys through gaps between laminations

11 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures 7. Eliminate masters (I) Masters are eliminated. Bladders / load keys are installed between yoke and load pads. Pads locate to collars at angled surfaces (as masters did 2x) Pads key directly to yokes Revised QXF magnet cross section

12 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures 7. Eliminate masters (II) Load pads are pre- assembled in the yoke shell subassembly Temporary, intermittent bolts secure load pads in retracted position. Bolts are installed only at existing cutouts at ends of shells. Yoke-Shell subassembly now includes pads

13 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures 7. Eliminate masters (III) Collar assembly supported on roller assemblies, roller tracks inserted in yoke holes Once collar assembly is in place, pad retention screws are removed and in their place jacking screw assemblies used to push pads into position against collars to increase space for bladder installation. Note: requires holes in table base at bottom screw locations Cheaper insertion rail concept if desired; simpler support bar sliding on low friction UHMW bar. Collar Pack Insertion Jacking screw thread region

14 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Cutouts for yoke fiducials at each shell end causes increased deflections, ~20 MPa coil stress variation at those locations Compensating axial grooves in shell centers can eliminate variations, increase assembly tolerance margins 8. “tune” aluminum support shells to reduce coil stress variations along the axial direction

15 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures 9., 10. Utilize full length keys, bladders, Utilize extruded bladders 4.2 m (Q1/Q3 full length) keys, bladders: Easier to pull (and push if needed) for insertion as well as removal Extruded bladders: Less susceptible to leaks by virtue of elimination of seam welds Maximum displacement > 5 mm Load is not reduced with increasing pressure (i.e., surface area is constant) Works with backing bar as in present QXF bladder For test, formed out of tube. For production, buy extrusion & flare ends Pressurized to 8000 psi (55 MPa), achieved 6.3 mm travel without problem. Assembly & test fixture Tested bladder Forming tool

16 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures 11. “four-fold” bladder pressurization Symmetric bladder / key loading at assembly eliminates shear on G-10 keys, improves final alignment after assembly 4 x more incremental pressures (i.e. smaller steps) ÷ 4 locations shimmed at each step results in: —equal ease of installation — similar assembly times

17 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Bonus Candidates for consideration Coils: Eliminate curing of outer layer; install directly into reaction fixture Eliminate inner trace Structure: Eliminate “Fuji film” inspection assembly

18 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Thank you for your attention

19 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Appendix Formblock Fabrication Steps

20 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Step 1 – initial milling of tooling halves & drilling holes* * some used for temporary bolting together of halves

21 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Step 2 – bolt halves together & gun drill to undersized radius

22 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Step 3 – separate and machine each half to larger undersized radius, accurately machine midplane and machine overall height

23 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Step 4 – bolt halves together and hone radius to final dimension Ø ± mm

24 MQXF Workshop on Structure, Alignment, and Electrical QA Feb 2-4, 2016 Options for modifications to parts and procedures Ref - QXF Baseline Design