1. Industrialization Studies in the KEK Cavity Fabrication Facility (CFF) H. Hayano 07242011 The 2nd workshop on SCRF Cavity Technology and Industrialization for the ILC @Chicago,July 2011 S. Yamaguchi, K. Ueno, T. Saeki, H. Inoue, Y. Ajima, Y. Watanabe, K. Enami, S. Koike, S. Kato, E. Kako, Y. Yamamoto, A. Yamamoto; KEK 1

2. KEK Cavity Fabrication Facility(CFF): main R&D Center cell R&D End-group R&D EBW Quality Control Technology ( multi-dumbbell, multi-cell, multi-cavity Jigs for EBW ) Deep Drawing Technology Fine-blanking (Water-jet cut) and Press-forming Technology ( End-group Jigs for EBW ) KEK initiative on mass-production technology R&D in CFF KEK also like to invite industry participation in CFF it will start soon. ✓ ✓ ✓ 2

3. KEK Cavity Fabrication Facility Building inside Plant clean room Chemical Room Trimming Machine Press Machine EBW Crane range Inspection area 19m x 14m clean room STF ATF 3

4. 12 th April 2011 EBW delivery on April 12, 2011 4

5. SST EBOCAM KS-110 – G150KM Chamber (Stainless Steel chamber) Main Machines in the facility EBWPressTrim AMADA digital-survo-press SDE1522 150t, 50stroke/min, 225mmstroke MORI VKL-253 Vertical CNC lathe Chemi-room Tape-cut Ceremony on July 13,2011 for EBW operation start. 5

6. Center Cell Fabrication R&D KEK 9cell cavity #0 (w/o HOM couplers) fabrication 6

7. Press, Trim, EBW R&D before KEK-EBW delivery by using EBW Job-shop EBW at Tosei-electrobeam co., Tokyo (SST-EBW) Cell Press at KEKTrimming at KEKStiffener Press at KEK BCP at KEK 7

8. Dumbbell EBW at Job-shop (Dec.2010 – Feb.2011) Total 13 dumbbells were fabricated. 8 of them went to cavity fabrication 8

9. stretching of dumbbell stiffener insertion after insertion Stiffener Insertion and EBW EBW settingStiffener EBW After Stiffener EBW 9

10. 2 - Dumbbell EBW at Job-shop (Dec.2010 – Feb.2011) 10

11. 30 June 2011 4 – Dumbbell, 8 - Dumbbell EBW at Job-shop (June.2011 – July 2011) Beam 8 July 2011 6 July 2011 11

12. 8 - Dumbbell EBW-Seam inspection * End-group fabrication will be done in September – October, 2011, right after delivery of Nb pipes. KEK –EBW machine will be used there. Center cell equater: typical seam Center cell equater: seam end 12

13. End Group Fabrication R&D 13

14. KEK-End-Group, KEK-HOM-coupler At First, we started HOM coupler fabrication study (1) Deep Drawing of HOM-cup, (2) Cut-out of holes, or Burring of holes. (3) Develop cost effective shape of tuning knob. (4) Press cut-out from thick plate, (5) Press cut-out of slope region, (6) Press forming into design shape 14

15. Blank diameter: 120mm Inner diameter : 40mm Cup height : 65mm One press-action Deep drawing First step study : Using existing press-setup, 1.5mm Nb sheets were deep-drawn into cup, by one press-action. 15

16. HOM-cup Tuning-Knob forming First step study : Using existing press-setup, deep-drawn cup bottom shape and knob were formed, by two press-action. Knob: 10mm diameter, 6mm height 16

17. Study of Press-forming is underway Water-Jet cut Press forming of Nb HOM Antenna press forming HOM Antenna forming 17

18. Mass-production R&D, others 18

19. Idea of Multi-action Press for cell forming 19 Conceptual design of automated cell-press KEK-Shinohara Press *Automated product transfer mechanism in the press machine are also under design.

20. 20 reception Eddy-current scan Press forming TrimmingInspection CP stock EBW Bulk EP anneal Inspection Tuning machine Jacket Stock area AC power area Plant Simulation study using CFF housing area （ 53m x 30m ） Assuming Nb plates for cell, fabricated end-group parts are input, 200 working days/year, 2 shifts/day with 30 people times 2 shifts Max. production rate will be ~530 cavities/year, ~2650 cavities for 5years. Estimation of cavity production plant KEK-MHI Assuming that final treatment and vertical test will be done in other place. parts delivery shipping of jacketed cavity

21. 21 cavities Vacuum vessel, themal shield KEK-Hitachi Cold-mass, thermal shield Estimation of cryomodule assembly plant Assembly Plant Analysis using KEK assembly hall area （ 120m x 50m ） Assuming VT-passed cavity, fabricated cold-mass parts, vaccum cessel are input, 200 working days/year, 2 shifts/day with 37 people times 2 shifts Max. production rate will be ~57 cryomodules/year, ~285 cryomodules for 5years. Assuming that cryomodule power test will be done in other place.

22. 22 Concept of rotational jig for multi-dumbbell and end-parts EBW Conceptual Design Study

23. 23 Concept of EBW rotational jig for multi 9 cell cavities Conceptual Design Study

24. Schedule Plan 24

25. CFF schedule plan for industrialization 7,8,910,11,12 1,2,3 4,5,6 7,8,9 10,11,121,2,3 4,5,6 7,8,9 2011 2013 KEK-#0 w/o HOM fabrication EP, VT EBW fixture development operation and upgrade 2012 KEK #1 KEK #2 KEK #3 Design of multi-dumbbell fixture EP, VT HPV application fabricationoperation and upgrade Design of multi 9-cell cavity fixture fabricationoperation and upgrade Design of endgroup EBW fixture KEK #4 KEK #5 KEK #6 EP, VT Jacketing HPV inspection Trim fixture development fabrication operation and upgrade Design Automated BCP fabrication operation and upgrade Design Deep-drawing, Forming press development Basic R&D deep drawing jig fabrication operation and upgrade Design of press- shape 2011 materials procurement CFF industrial production 2012 materials procurement Hayano’s proposal; June 2011 25

26. STF Plans for cavity production and test CY2011 CY2012 CY2013 CY2014 S1-Global cryomodule STF phase-2 Phase2 Injector part operation as “Quantum-Beam Project” 1st Cryomodule Phase2 CM-2 construction or cavities replacement of CM-1 operation Phase-2 Injector construction Phase2 CM-1 cryomodule construction Cavity Fabrication Facility Startup & EBW jig constructionCFF Industrialization Operational (4 cavities/year) operation KEK EBW operational 1st cavity2 nd cavity, 3 rd, 4 th, …. operation finished CY2015CY2016 disassembly cavity replace operation 26 Start beam operation ILC Cryomodule operation Cavity Industrialization Start cavity replace 4 cavities/year from Industries

27. Summary R&D status of KEK Cavity Fabrication Facility Center cell R&D End-group R&D 1. EBW Technology Experience through KEK-#0 9-cell cavity (w/o HOM) production. 2. By using EBW job-shop, center cell part was finished its fabrication. 3. After Nb pipes delivery, end group fabrication will be done in September – October, 2011, by using KEK EBW. 1. R&D on Deep Drawing Technology, Press forming technology are on-going. 2. Using existing press setup, possibility of end group parts fabrication from Nb sheet and from Nb thick sheet is under demonstration. Mass-production Studies 1. Conceptual Design Studies on Press-forming and EBW is started. 2. Cavity production plant and Cryomodule assembly plant are in study. End 27 Cavities by CFF, and cavities from industries, will be tested in cryomodule.