1. EN/MME fabrication activities and developments for CLIC
A Contribution of CLIC study teams in BE ,EN department and several collaborations
"Alpenveilchen zu Weihnachten"  Ernst Ludwig Kirchner 1917 
17/12/2008
S. Atieh EN/MME

2. Structure production (2008/2009)
G. Riddone
RF design
BE/RF
Mechanical design
BE/RF
Tendering
EN/MME
BE/RF
All activities coordinated in mechanical design, production
and collaboration meetings
Decision point based on experimental results
Fabrication
EN/MME
Preparation and Assembly
TE/VSC, BE/RF QC
Dimensional control
SEM EN/MME
RF check BE/RF
17/12/2008
S. Atieh EN/MME

3. Technical specification.
Analysis.& feedback.
Fabrication.
Preparation.
Fabrication
Materials.
Test Analysis
Structure RF design
Structure life cycle
Structure fabrication
RF Model
preparation
Materials
R&D
KEK
SLAC
CTF3
17/12/2008
S. Atieh EN/MME

4. Functional organisation of EN/MME for CLIC accelerating structures 2009
Projet CLIC
Ingénierie des materiaux
G. Arnau Izquierdo
Ingénierie fabrication
S. Atieh
Approbation plans
Estimations sur plans
Expertise technique
Revues périodiques
Pièces haute précision?
Oui
Choix des matériaux
Mécanique
Non
Coordination interne
Rapports de synthèse
Réunions d’information
matière première et contrôle qualité
Sous-traitance FI
Assemblage
Métallurgie
Morphologie
Métrologie
EN/MME
EDMS
TS/MME
17/12/2008
S. Atieh EN/MME

5. Activities 2008 453 heures de contrôles ~ 50 rapports de mesure
Metrology: A. Cherif/D. Glaude
453 heures de contrôles
Rugosité
Tridimensionnel
~ 50 rapports de mesure
Performances machines :
Mesure de rugosité :  machine en adéquation
Mesure tridimensionnelle : 
Incertitude machine trop élevée
17/12/2008
S. Atieh EN/MME

6. Mesures tridimensionnelles

7. Activities 2008 Machining Assembly Heat treatment Sheet Forming
Mechanics and Assembly: J.M. Geisser/ S. Mathot/G. Favre
Machining
Assembly
Heat treatment
Sheet Forming
Forming (WG)
Laser welding
EB welding
µ TIG welding
17/12/2008
S. Atieh EN/MME

8. Accelerating structures in disc
Structure fabrication in discs, SPDT (single point Diamond Tuning) )
SA: iris shape accuracy
OD: outer diameter
ID: inner diameter
Th: iris thickness
Ra: roughness
specifications: 4 µm shape tolerance
by SPDT (single point Diamond Tuning)
Nominal
Achieved
17/12/2008
S. Atieh EN/MME

9. Achieved shape accuracy/ISO 1101
Structure fabrication (in quadrant)
17/12/2008
S. Atieh EN/MME

10. KERN’s preliminary tests
Structure fabrication (in quadrant)
Several tests on brass, 9 pieces
HDS thick 30 GHz quadrant 50 mm
Requirements:
Shape accuracy 5 µm
Ra = 0.1 µm
Surprise by end of 2008
Program for 2009
Phase 1
1 quadrant at 30 GHz
Phase 2
1 PETS bar 300 mm
Phase 3
CD10 Cu
17/12/2008
S. Atieh EN/MME

11. KERN’s preliminary tests on brass HDS thick 30 GHz quadrant 50 mm
Structure fabrication (in quadrant)
Achieved shape accuracy ± 2.1 µm
Roughness Ra = 86 nm – 30 nm according to ISO 97
17/12/2008
S. Atieh EN/MME

12. KERN’s preliminary tests on brass HDS thick 30 GHz quadrant 50 mm
Structure fabrication (in quadrant)
Achieved shape accuracy ± 1.3 µm
17/12/2008
S. Atieh EN/MME

13. Qualification & fabrication
program 2009
VDL
Ac. structures in quadrants:
acc. structures in two halves
longer accelerating structures
Ac. structures in discs:
-radial choke damped acc. structures, CD10 based
- acc. structures with 140-mm diameter
LT ULTRA
Phase 1:
qualification disk: disk 10, CLIAAS st version.
Phase 2: full structure
CD10 in copper, 5 disks
CD10 in copper, full structure (deadline: 2Q in 2009)
CD10 in CuZr, full structure
CD10 in Glidcop® AL-15 , full structure
17/12/2008
S. Atieh EN/MME

14. Qualification & fabrication
program 2009
KUGLER
Turning
now fabrication of 12WNDSvg1.8.Cu
CD10, 5 X Choke damped disks in copper
C10, 5 X undamped in CuZr
C10, 5 X undamped in Glidcop
Milling
Phase 1: HDS thick 30 GHz quadrant 50 mm
1 piece (deadline: end of February 2009) – CLIAS300062
4 pieces, including assembly
Phase 2: 1 X 300 mm PETS
Phase 3: 300 mm structure in halves → end of 2009
17/12/2008
S. Atieh EN/MME

15. Achievable surface roughness by milling
R&D
Theoretical surface roughness for turning or face milling tools with round cutting edges.
The achieved surface roughness by milling using carbide tools is around Ra = 0.4 µm
The achieved surface roughness by milling using single crystal diamond tools is around
Ra = 0.1 – 0.2 µm using a feed of 12 µm
single crystal diamond tools
- Ra = 0.1 – 0.2 µm using
- feed of 12 µm
- 190 hours continuous machining only for finishing a 250 mm quadrant
17/12/2008
S. Atieh EN/MME

16. Roughness f(material, process)
R&D: Vital questions, machining of GLIDCOP by diamond tools?
Technique
Material
UNS C10100
Cu-OFE
UNS C15000
CuZr
UNS C15715
GLIDCOP® AL-15
Machining by milling
Ra 150 nm
To be done
Ra 350 nm
DFC
Ra 1.7 nm
Ra 17 nm
Ra 8 nm
SPDT
Ra 10 nm
Newly-married : Diamond cutting tools and UNS C15715
SPDT (Single Point Diamond Tuning)
DFC (Diamond Fly Cutting)
GLIDCOP® is Copper Dispersion Strengthened with Aluminium Oxide (Aluminium Oxide 0.3 wt%)
17/12/2008
S. Atieh EN/MME

17. Assembly
R&D: Vital questions, machining and assembly of CuZr (UNS C 15000) ?
different assembly techniques (EB welding and vacuum brazing)
material
dimension x
technique
analysis
Ø 100 HE
Ø 80 mm x8mm 6
Brazing
Brazing aspects
Geometrical
Metallographic
Ø 50 CW 60%
30 mm x 30 mm x 200 mm 4 EB
Leak - tightness
∑ = 20 kCHF
The aim of this proposition is to investigate the workability of CuZr (UNS C 15000) as a potential candidate for CLIC accelerating structures in term of machinability and different joining techniques.
17/12/2008
S. Atieh EN/MME

18. MMP Non conventional machining
MMP is a micro-machining process intended for the super finishing of surfaces of metallic parts in a completely automated mode. It allows, by a mechanical- chemical reaction, a removal of matter from 1 to 40 µm and generates a surface state whose roughness can reach or to be higher than N1 on the ISO scale.
Non traditional machining operation could be capable to produce the aimed roughness and surface softening essentially free of metallurgical surface layer alternation
17/12/2008
S. Atieh EN/MME
* Courtesy B i n C

19. A lot of R&D fields to be explored : → Conventional machining:
Conclusion
The precision mechanics market is growing annually, namely due to the trend towards miniaturization of technology, the interest of European industry in CLIC is growing too.
A lot of R&D fields to be explored :
→ Conventional machining:
Tool characterisation
Software method
Machining time
Materials
Etc.
→ Non conventional machining:
ECM
MMP
Different materials
→ Hybrid machining
→ not to be forgotten: the Assembly aspects
17/12/2008
S. Atieh EN/MME

20. Thank you for your attention Thank you for your contribution
17/12/2008
S. Atieh EN/MME

21. Achieved shape / CLIAAS300052
Qualification piece: HDS 11 R1.6 / in C 15000
Ferranti ± 3 µm, T = 20°C ± 1°C
Deviation:
min: - 4 µm
max: +39 µm
Temperature regulation
Incorrect tools choice and characterisation
Exposition machine (time)
17/12/2008
S. Atieh EN/MME

22. Dimensional control Requirements: +/- 5 micro S. Atieh EN/MME
17/12/2008

23. Différents types de pièces mesurées

24. Mesures de rugosité