QXF Coil Fabrication: Baseline Decisions QXF Coil Working Group Video Meeting (Revised from discussion during presentation) Dan Cheng April 16, 2013

QXF Coil Fabrication Baseline Overview Some baseline decisions were made during the LARP CM20/HiLumi meeting in Napa These decisions were reviewed during the Coil WG video meeting 4/16/13, and some issues were raised with respect to some of the decisions made. The following slides outline only what has been decided as a baseline. See the notes for the complete discussion on other issues April 16, 2013 D.W. Cheng - QXF Coil WG Video Mtg.2

Outline of Coil Fabrication Baseline Baseline decisions – Coil Parts Design – Coil Winding – Coil Curing – Coil Reaction – Coil Impregnation – Coil Instrumentation April 16, 2013 D.W. Cheng - QXF Coil WG Video Mtg.3

QXF COIL FABRICATION: BASELINE DECISIONS April 16, 2013 D.W. Cheng - QXF Coil WG Video Mtg.4

Coil Parts Baseline CERN to purchase parts through their RP DMLS (Direct Metal Laser Sintering) vendor (cheaper/faster than available in US) Plasma coating only on the OD of the end spacers, endshoes, and endshoe (splice) extensions (L1, L2) No plasma coating on the pole islands – Thick tape around the pole island (.015”/381µm) G11 alignment keys will be used Do not slit endshoes for fit End shoe extension – 140 mm long, for full splice; will not remove endshoe to make splice – Assumes max 117mm pitch length + 2-3mm and 20 mm for VT SQXF length will be set at 1.51 m April 16, 2013 D.W. Cheng - QXF Coil WG Video Mtg.5 Courtesy: G. Kirby Design Fab. Fit

Coil Winding Baseline Coil winding will use winding tool – Curing matrix will only be used for cases where a popped strand cannot be manipulated back into position with normal means Winding tension & cable twist – 10kg for first turn – 25kg for subsequent turns – No cable twist between spool & coil Intralayer Insulation will be cured – “Hybrid” curing where the ends are left uncured will be explored with HQ/LHQ processing April 16, 2013 D.W. Cheng - QXF Coil WG Video Mtg.6

Coil Curing Baseline Coils will be cured without the addition of extra shims on midplane Replaceable curing endshoes will be used. – HQ and LHQ windings will test both the split and short-leg replaceable endshoes Real endshoes will not be split, and they will be full-length legs April 16, 2013 D.W. Cheng - QXF Coil WG Video Mtg.7

Coil Reaction Baseline Wedges are currently using C510 Phosphor bronze – ODS Copper C15715 (Glidcop AL-15) may be explored if necessary, since it has better post-thermal cycle properties QXF Practice coils will be designed for open pole gaps after reaction April 16, 2013 D.W. Cheng - QXF Coil WG Video Mtg.8 HQ Coil 17 post-reaction pole gap

Coil Impregnation Baseline Coils will be impregnated with CTD 101K epoxy – CERN’s latest data seems to indicate rad-hardness is acceptable Technical challenges for impregnation using Cyanate Ester blends (or other materials) likely to be pursued outside of LARP April 16, 2013 D.W. Cheng - QXF Coil WG Video Mtg.9

Coil Instrumentation Baseline Wiring – Non-Teflon-insulated wiring to be specified for instrumentation that will be found in production magnets – Wiring for other R&D-only instrumentation can continue to use Teflon Traces – ID trace only required for voltage taps, no protection heaters – OD trace to have both voltage taps and protection heaters April 16, 2013 D.W. Cheng - QXF Coil WG Video Mtg.10 Instrumentation wire routing of LQS03 at Lead End.

Inspection & QA Baseline CMM – All Labs to use same reference models April 16, 2013 D.W. Cheng - QXF Coil WG Video Mtg.11

Appendix April 16, 2013 D.W. Cheng - QXF Coil WG Video Mtg.12