1. CDR2 – Coupler Mechanical Design NICOLAS MISIARA

2. PRELIMINARY VERSION SUMMARY 1.Requirements 2.Interfaces 1. Interface on the RFQ 2. Interface on the Test Cavity 3. Interface with the RF Transition 3.Power Coupling 4.Mechanical Design 1. Ceramic window 2. Loop 3. Cooling system 4. Monitoring 5. Qualification of the manufacturing process 5.Mechanical simulations | PAGE 2 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

3. PRELIMINARY VERSION 1. REQUIREMENTS CEA IDParameterValue RFQ-L4-EMR-80 RFQ-L4-EMR-280 Max forward peak RF power coupler handling 1 MW RFQ-L4-EMR-90 RF coupler matching15dB < forward RF power ACC-EMR-VAC-060 Vacuum gauge for coupler1 per coupler RFCIC-100 + 110 Ark detector on SMA viewport on vacuum and air side2x(1 per coupler) RFCIC-200 Electron pick-up on vacuum side of the coupler1 per coupler | PAGE 3 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA RF design hasn’t been modified since CDR 1. Réf. 4

4. PRELIMINARY VERSION 2. INTERFACES 1. Interface on the RFQ 2 Couplers installed on S3 Tuners Cooling Vacuum Gauges … | PAGE 4 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

5. PRELIMINARY VERSION 2. INTERFACES | PAGE 5 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

6. PRELIMINARY VERSION 2. INTERFACES 2. Interfaces on the Test Cavity (vacuum side) Same interfaces as the RFQ (diameter, gap etc…) Length of the port Gap =>8.1mm | PAGE 6 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

7. PRELIMINARY VERSION 2. INTERFACES 3. Interfaces with the RF Transition (air side) Identical interface for RF Transition (coupler on RFQ and Test Cavity) Standard coaxial connexion Adaptator SMS clamp to 4’’1/2 EIA (Réf. Spinner BN 532766) | PAGE 7 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

8. PRELIMINARY VERSION 3. POWER COUPLING Coupling performed by rotating the coupler arround its rotation axis Specific flange allowing rotation without removing systematically the screws Vacuum thightness obtained with appropriate O-rings | PAGE 8 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

9. PRELIMINARY VERSION 4. MECHANICAL DESIGN 1. Ceramic window Alumina 97.6% pure Réf. Al300 Wesgo (6mm thick) TiN deposition | PAGE 9 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA Atmospheric pressure Vacuum Incident RF Power

10. PRELIMINARY VERSION 4. MECHANICAL DESIGN 2. Loop | PAGE 10 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA Réf. 1 and 2 Réf. 3 Power density [W/cm 2 ] PRF = 1MW, duty cycle = 5% Coupler RF design Mean power deposition : Internal coaxial conductor : 10.3 W External coaxial conductor : 5.8 W Body : 22W RF Loop : 34.2W

11. PRELIMINARY VERSION 4. MECHANICAL DESIGN 2. Loop Conclusion : h = 1000 [W.m -2.K -1 ] optimal heat exchange coefficient | PAGE 11 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA Thermally induced displacements [µm] Elevation temperature field [K] dT=16.3 [K] dl=29.8 [µm]

12. PRELIMINARY VERSION 4. MECHANICAL DESIGN 2. Loop Complex geometry, compliant to the simulations One « leg » concentric to the axis of the Coupler Feedback from previous tender | PAGE 12 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

13. PRELIMINARY VERSION 4. MECHANICAL DESIGN 3. Cooling system Volumetric flow of water : 4L/min Pressure drop : approximately 1.2 Bars Standard Swagelok connections | PAGE 13 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

14. PRELIMINARY VERSION 4. MECHANICAL DESIGN 3. Cooling system Not necessary to cool the alumina from its outter diameter Margin-taking, TBD during conditionning Volumetric flow of water : 2-3 L/min Pressure drop : approximately 0.5 Bars Standard Swagelok connections | PAGE 14 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

15. PRELIMINARY VERSION 4. MECHANICAL DESIGN 4. Monitoring | PAGE 15 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA ElementQuantity Ark Detector2 RF Pick-up1 CC Gauge1

16. PRELIMINARY VERSION 4. MECHANICAL DESIGN 5. Qualification of the manufacturing process Does the manufacturing process meets the requirements => performances ? Step 1 : « Prototype » RF window Machining requirements =>Dimensional tolerances (mm) =>Surface roughness : Ra 0.8 Assembling requirements =>Dimensional tolerances (mm) =>Vacuum tightness : 10 -11 Pa.m 3 /s He leak test RF performance =>Low level RF test before AND after TiN deposition | PAGE 16 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

17. PRELIMINARY VERSION 4. MECHANICAL DESIGN 5. Qualification of the manufacturing process Step 2 : « Prototype » loop Machining requirements =>Dimensional tolerances (mm) =>Surface roughness : Ra 0.8 Assembling requirements =>Dimensional tolerances (mm) =>Vacuum tightness : 10 -11 Pa.m 3 /s He leak test =>Hydraulic tightness : 10 Bars pressure test | PAGE 17 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

18. PRELIMINARY VERSION 4. MECHANICAL DESIGN 5. Qualification of the manufacturing process Step 3 : TiN (Titanium Nitride) deposition samples Thickness =>10nm +/- 5nm Deposition homogeneity Stoichiometric composition | PAGE 18 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

19. PRELIMINARY VERSION 5. MECHANICAL SIMULATIONS 1. FE Analysis Static Structural : Coupler on the RFQ | PAGE 19 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

20. PRELIMINARY VERSION 5. MECHANICAL SIMULATIONS Maximum Vertical Displacement : approximately 0.011mm | PAGE 20 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

21. PRELIMINARY VERSION 5. MECHANICAL SIMULATIONS Equivalent Von-Mises Stresses : approximately 3.3MPa | PAGE 21 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

22. PRELIMINARY VERSION 5. MECHANICAL SIMULATIONS 2. FE Analysis Static Structural : Coupler on the RFQ + RF Transition connexion | PAGE 22 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

23. PRELIMINARY VERSION 5. MECHANICAL SIMULATIONS Maximum Vertical Displacement : approximately 0.018mm | PAGE 23 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

24. PRELIMINARY VERSION 5. MECHANICAL SIMULATIONS Equivalent Von-Mises Stresses : approximately 20MPa | PAGE 24 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

25. PRELIMINARY VERSION 5. MECHANICAL SIMULATIONS Equivalent Von-Mises Stresses : approximately 20MPa | PAGE 25 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

26. PRELIMINARY VERSION 5. MECHANICAL SIMULATIONS Equivalent Von-Mises Stresses : approximately 20MPa (Tension and Compression) | PAGE 26 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA

27. PRELIMINARY VERSION THANKS FOR YOUR ATTENTION References : 1. ESS-0021319 : Report for CDR RFQ 2. ESS RFQ – RF Design A. C. FRANCE, M. DESMONS, O. PIQUET 2014/11/18 3. CEA Internal Note : Contraintes_Coupleur_RFQ_ESS (Thermal simulations) 4. RFQ Interface « L3_L4_WTRC_Vac_req_review_V18 » 2015/11/11 | PAGE 27 2015/12/08 CDR2 - Mechanical Design of the Coupler – Nicolas MISIARA