1. Research and development for future LHC Superconducting Magnets WP status
J.M. Rifflet – Steering committee –January 09th 2015

2. Les 7 Work-packages Description CERN CEA WP1
Coordination and monitoring of activities
L. Bottura
J.M. Rifflet
WP2
Design and prototyping of a new Nb-Ti Q4 pour HL-LHC
E. Todesco
M. Segreti
WP3
Completion of the Nb3Sn magnet FRESCA2 and participation to the tests
P. Ferracin
F. Rondeaux
WP4
Support in the Nb3Sn technology R&D
J.C. Perez
M. Durante
WP5
Completion of the HTS insert winding for FRESCA2 
G. De Rijk
WP6
Study of HTS magnets at high field
Ph. Fazilleau
WP7
Mechanical study of Rutherford cable
L. Oberli
P. Manil
Merci à eux pour les infos contenues dans cette présentation
CERN-CEA collaboration – Steering committee -09 janvier 2015

3. WP2 : Q4 Magnets for LHC Upgrade
CERN-CEA collaboration – Steering committee -09 janvier 2015

4. Q4 Magnets : Contenu de la tâche
Sur la base de l’étude de la design study Hilumi WP3.5:
1) Study, realization and cold test of one single aperture magnet short model:
Conceptual & CAD studies
Manufacture zone adaptation
Specifications and call for tenders, Follow-up of tooling and components realization
Coil 0 manufacture  collaring test
4 coils manufacture, instrumentation, collaring
Cold test facility adaptation
Cold test of the single aperture short model
Winding of 2 additional sets of coils
2) Study of the cold mass (quad + correctors) and integration in accelerator (CM conceptual & CAD studies, interfaces and tooling definition, assembly procedure of the cold mass).
CERN-CEA collaboration – Steering committee -09 janvier 2015

5. Magnetic design WP2 - Q4 magnets for HL-LHC
Little change of the hole position in the iron yoke for the heat exchanger
Meeting Collaboration, Steering Committee CERN-CEA |
| P 5

6. Magnetic design WP2 - Q4 magnets for HL-LHC
Heat exchanger and cold bore are farther now  this gives more space for the welding and cutting machine
b3 coming from cross-talk is now minimized by means of 20 mm diameter holes near the magnet center
this change for heat exchanger position in the corrector magnets for Q4 has tro be taken into account for correctors design
Meeting Collaboration, Steering Committee CERN-CEA |
| P 6

7. Hilumi WP2 interaction WP2 - Q4 magnets for HL-LHC
Demand for cycling at low current to investigate the effects on the field quality
Meeting Collaboration, Steering Committee CERN-CEA |
| P 7

8. Coil ends WP2 - Q4 magnets for HL-LHC
3D calculations realized again, but with the last version of ROXIE  some change needed to smooth the curves
Optimization by minimizing:
the strain energy of the cable
b6 integrated at lead-end and return-end
the peak field
One of the challenges is the specific cable output
Meeting Collaboration, Steering Committee CERN-CEA |
| P 8

9. Drawing office WP2 - Q4 magnets for HL-LHC
Work at drawing office started only on September 2014 (no availability before)
People from the drawing office affected to the Q4 project:
1 engineer (30%)
1 designer (50%)
1 other designer is planned for the beginning of 2015
Meeting Collaboration, Steering Committee CERN-CEA |
| P 9

10. Winding trial WP2 - Q4 magnets for HL-LHC
A winding trial will validate the geometry of the end-spacers
40 m of insulated cable were sent from Cern. This length is sufficient to make two 700-mm-long mockups
Drawings for the winding trial of a 700-mm-long mockup is finished. It includes:
The components (cable, end-spacers, wedges and the special support of the specific cable output).
The tooling (mandrel, accessories)
Meeting Collaboration, Steering Committee CERN-CEA |
| P 10

11. Winding trial WP2 - Q4 magnets for HL-LHC
The Cern routine allowed to obtain rapidly the CAD of end-spacers from ROXIE output files
A first set of end-spacers was 3D printed in plastic material at the design office
A second set is printed at Cern with Bluestone composite material which can survive to the curing temperature
The tooling and accessories for the winding trial are entirely realized
The winding trial will be performed on first half of January 2015
Meeting Collaboration, Steering Committee CERN-CEA |
| P 11

12. No budget planed for test station adaptation
WP2 - Q4 magnets for HL-LHC
Cold test of the single aperture short model
The baseline is that the test of the single aperture short model will be done at CEA-Saclay
The solution could be to use the 8 m vertical cryostat
Verification is still in course, but the biggest issue is that for now, no current leads are available for a test at 20 kA at Saclay
No budget planed for test station adaptation
Philippe BREDY will give the technical characteristics of the needed current leads
In any cases, Cern should provide the entire measurements system
Meeting Collaboration, Steering Committee CERN-CEA |
| P 12

13. Milestones and deliverables
WP2 - Q4 magnets for HL-LHC
Milestones and deliverables
No change since the kick-off of July 2014 N°
Description
Actual collaboration agreement
Today
2.1
Complete design of the single aperture magnet short model
December 2014
April 2015
2.2
Winding and polymerization of short coil 0
August 2015
January 2016
2.3
Completion of all coils (3 sets in total)
July 2016
2.4
Single aperture magnet short model assembly
February 2016
September 2016
2.5
Assembly procedure end of cold mass (quad + correctors)
December 2016
Meeting Collaboration, Steering Committee CERN-CEA |

14. Planning WP2 - Q4 magnets for HL-LHC
Meeting Collaboration, Steering Committee CERN-CEA |

15. WP3 : FRESCA2 Magnet
CERN-CEA collaboration – Steering committee -09 janvier 2015

16. Fresca2 Magnet: Contenu de la tâche
Fabrication d’une bobine Cu type 3-4 avec outillage modidié
Fabrication de 2 bobines Nb3Sn type 1-2
Assemblage et test, dans la structure des 2 bobines Nb3Sn type 1-2 avec 2 bobines Cu type 3-4
Fabrication de 2 bobines Nb3Sn type 3-4 pour le dipôle FRESCA2
Assemblage et test du dipôle FRESCA2
CERN-CEA collaboration – Steering committee -09 janvier 2015

17. Status 2 copper coils already partially done : CC3401 (type 3-4):
winding OK, sent to CERN (25/06/2013)
heat treatment OK
impregnation OK
CC1201 (type 1-2)
winding OK, sent to CERN (07/01/2014)
CERN-CEA collaboration – Steering committee -09 janvier 2015

18. Modified winding / reaction tooling
We have received the modified winding / reaction tooling (in 3 parts) for type
Test on coil (4+4 turns of RRP cable) with modified tooling + large gaps (DR3401) :
OK, cf. next slide
Test on coil (4+4 turns) with modified tooling + adjusted gaps (DR3402) :
winding OK, waiting for the new guiding rings
Procurement of the modified tooling for type 1-2: delivery in early April
CERN-CEA collaboration – Steering committee -09 janvier 2015

19. DR3401 It moved! 1,9 mm sym side + 1,3 mm asym side
¾ ceramic guiding rings broken
will be modified
CERN-CEA collaboration – Steering committee -09 janvier 2015

20. Milestones 2 options: 1) strategy maintained with intermediate test.
2) without intermediate test (and CC3402).
Option 1
Kick-off meeting 
Today
3.1 : 1 Cu coil type 3-4 with modified tooling
March 2015
June 2015
3.2 : 2 Nb3Sn coils type 1-2 for FRESCA 2 magnet delivered
September 2015
December 2015
3.3 : 2 Nb3Sn coils type 1-2 tested with 2 Cu coils
February 2016
May 2016
3.4 : 2 Nb3Sn coils type 3-4 for FRESCA 2 magnet delivered
3.5 : FRESCA 2 magnet tested
August 2016
November 2016
Option 2
Kick-off meeting 
Today
3.2 : 2 Nb3Sn coils type 1-2 for FRESCA 2 magnet delivered
September 2015
November 2015
3.4 : 2 Nb3Sn coils type 3-4 for FRESCA 2 magnet delivered
February 2016
3.5 : FRESCA 2 magnet tested
August 2016
June 2016
CERN-CEA collaboration – Steering committee -09 janvier 2015

21. We are in favour of option 2. Does the committee confirm this option?
Pro:
Validation and adjustment of assembly procedure
Detection of big problem on 1-2 Nb3Sn coils
Cons:
Risk of damage 1-2 Nb3Sn coils during assembly with dummy Cu coils and desassembly
Etienne Rochepault study : with the same level of stress, only 10.5 T central field (do we detect problems ?)
coils 3-4 in Nb3Sn not tested
Time lost because test and desassembly for intermediate test are on the critical path
Option 2
Pro
Planning
Cons:
First real assembly with Nb3Sn
Risk of assemble
Need of Nb3Sn cable in March
We are in favour of option 2. Does the committee confirm this option?
CERN-CEA collaboration – Steering committee -09 janvier 2015

22. Option 1
Option 2
CERN-CEA collaboration – Steering committee -09 janvier 2015

23. WP4 : Nb3Sn Technology development
CERN-CEA collaboration – Steering committee -09 janvier 2015

24. Nb3Sn Technology development : Contenu de la tâche
Tests de dilatation pendant la réaction thermique de formation du supra
Mesures dimensionnelles sur « ten-stack » imprégné ou non, avant et après réaction)
Mesures de rétreint thermique .
CERN-CEA collaboration – Steering committee -09 janvier 2015

25. Dilatation tests
1 full scale dilatation test (2 x 4 turns on 3-4 tool) has been performed
Second full scale dilatation test:
Winding finished
Will be send to CERN for heat treatment very soon.
Sym Gauche
Sym Droit
Asym Gauche
Asym Droit
After winding
9,7
9,75
5,93
Sortie du four
7,84
7,79
4,57
4,58
Ecart
-1,86
-1,96
-1,36
-1,35
moyenne
-1,91
CERN-CEA collaboration – Steering committee -09 janvier 2015

26. Total gap (central - lateral)
Dilatation tests
2 reduced scale dilatation tests with insulated RRP Nb3Sn cable have been performed
Titanium mandrel Iron mandrel
There are still discrepancies to understand (Iron – Titanium)
Mandrel material C1
Gap reduction
L SS
= 600 mm
L TOT
= 690 mm
L cable
= mm
1 central gap
% L SS
% L TOT (head to head)
% L cable
Titanium
Bare cable
HT10
Central gap
4.89 mm
0.8%
0.7%
Total gap (central - lateral)
3.97 mm
0.6%
0.5%
Insulated cable
HT11
4.85 mm
4.45 mm
Iron
Insulated cable “free”
3.62 mm
0.76 mm
0.1%
CERN-CEA collaboration – Steering committee -09 janvier 2015

27. Milestones N° Description Kick off meeting Today 4.1
Mechanical test facilities design
September 2014
4.2
Mechanical test facilities ready
December 2014
4.3
Dilatation tests report – preliminary
July 2014
To be sent
4.4
Dilatation tests report - final
April 2015
4.5
Report on Mechanical tests at Saclay
December 2015
CERN-CEA collaboration – Steering committee -09 janvier 2015

28. WP5 : HTc Insert
CERN-CEA collaboration – Steering committee -09 janvier 2015

29. HTc Insert : Contenu de la tâche
Bobine prototype de 270 mm de long : Etude de la dépendance de YBaCuO selon l’orientation du champ. Tests au LNCMI Grenoble
Réalisation de l’insert Htc:
Test de l’insert seul (à bas courant : ~100 A)
Test de l’ insert en champ externe (FRESCA2)
CERN-CEA collaboration – Steering committee -09 janvier 2015

30. Design review – first design
B0 = 6 T
Je= 250 A/mm2
Bpeak= 5,87 T
Inom = 2400 A
Electron-beam welding
CERN-CEA collaboration – Steering committee -09 janvier 2015
External pads, 316L
8/9 parts
Electron-beam welded
External tube, Nitronic 40
- 8 parts,
- Thermal shrinkage
- TIG welding
3 double layers coils
Glass epoxy inter-coil and external insulation
Iron pole
Compression plates, 316L

31. Pad is a structural component Pad is a filler
Design review
Proposal in order to decrease the stress in the pad : Do not weld the pad
Pad welded
Pad free
CERN-CEA collaboration – Steering committee -09 janvier 2015
welding
Pad is a structural component
429 MPa
Pad is a filler
160 MPa
Von Mises stress

32. Pad not welded  stress in the coil significantly lower
Design review
Pad not welded  stress in the coil significantly lower
Pad welded
Pad not welded
CERN-CEA collaboration – Steering committee -09 janvier 2015
1160 MPa
636 MPa
Von Mises stress in the coils

33. Updated design in 13 T background field
Tube thickness : 5.5 mm (against 3 mm in the former design)
VM stress (Pa)
822 Mpa < 1400 × 2/3 (900 Mpa)
CERN-CEA collaboration – Steering committee -09 janvier 2015
Material: Nitronic 40
Yield stress at 4 K: 1400 MPa (1000
Maximum deflection in x: mm

34. Updated design in 13 T background field
Coil 1
Coil 2
Coil 3
Old design
New design
Tube thickness (mm) 3
5.5
# turn coil 1
36 (73 total) 33
# turns coil 2
30 (61 total) 26
# turns coil 3
17 (35 total) 11
Joverall (A/mm2)
250
In (A)
2760
B0 (T)
6.0
5.4
-3 turns
-4turns
-6 turns
CERN-CEA collaboration – Steering committee -09 janvier 2015

35. Mechanical Structure Stand-alone mode
Phase I, stand-alone test : we will use a demountable mechanical structure (assembly less risky and faster, possibility to adjust the pre-stress, possibility to quickly and easily open the magnet)
Phase 2, test in Fresca 2 : demountable structure replaced by a tube (heat-shrink method)
CERN-CEA collaboration – Steering committee -09 janvier 2015
Phase 1
Phase 2

36. CAD detailed design ongoing
Magnet fabrication
CAD detailed design ongoing
New pads design
End saddles design taking into account new coil dimensions
Mechanical structure for standalone tests
Coil handling tooling (for magnet assembly)
Interface with the test station
CERN-CEA collaboration – Steering committee -09 janvier 2015
Row Material
Fabrication status
Delivery
Pole pieces
Procured
Completed
Delivered
End saddle
Pending -
Pad
Coil Insulation (G10)
External tube

37. Cable Magnet fabrication CuBe2 Stabliizer:
880 m of CuBe2 tape annealed at CEA (3h at 300 °C in Argon).
The order for the insulation of the CuBe2 tape has been placed
Insulation foreseen in January
HTS tape:
We have 2 unit lengts (UL) of 40 m.
We still miss the two 110 m UL and two 40 m UL (check with Amalia in course)
Dummy SS tape
to be delivered very soon (sent) dummy winding end of January)
CERN-CEA collaboration – Steering committee -09 janvier 2015

38. Winding tooling Magnet fabrication
Modification of the winding table is done
Use of small magnetic brakes partially validated with CuBe tape
Four more magnetic breaks (6 needed) ordered, to be delivered this week
Tape supports and guides during winding ordered, to be delivered by end of January
12 winding reels for the 6 tapes delivered
CERN-CEA collaboration – Steering committee -09 janvier 2015

39. Milestones N° Description Collaboration contract Kick off meeting 5.1
Test of the prototype at LNCMI
February 2014
September 2013
Test of a second prototype at LNCMI
March 2015
5.2
Construction of the insert
March 2014
June 2015
5.3
Test report of the insert inside FRESCA2
July 2016
September 2016*
CERN-CEA collaboration – Steering committee -09 janvier 2015
No change since kick-off meeting
*depending of FRESCA2 schedule

40. WP6 : High field magnet studies
CERN-CEA collaboration – Steering committee -09 janvier 2015

41. WP6: HIGH FIELD STUDIES
The work package deals with 20 T field accelerator-type configurations and its consequences on mechanics and materials:
The purpose of this work package is to study materials under the large stresses generated in such new configurations,
Which are the mechanical properties needed, depending on the layout configurations (figure below) and on the location inside the magnet,
Which materials are suitable for these properties ? Do they exist ?
We may need some measurements to find out the appropriate materials.
CERN-CEA collaboration – Steering committee -09 janvier 2015

42. WP6: HIGH FIELD STUDIES
0. Starting from J. von Nugteren study, 1. Selection of a limited number (3-4) of adequate configurations to study, 2. Mechanical study for each configuration: parametric analysis and FEM analysis, 3. Selection of appropriate materials and if needed, qualifications tests to perform, 4. Report
CERN-CEA collaboration – Steering committee -09 janvier 2015

43. WP6: HIGH FIELD STUDIES
The delivery of this work package is a report on mechanical studies,
The work estimated as 3 person.month has not started yet,
Chhon Pes, mecanical engineer, will perform the mechanical computations (CAST3M),
Small qualification tests could be foreseen: 1 engineer and 1 technician are estimated for this part of the duty.
Meeting at Saclay in January with J. von Nugteren to select the adequate configurations to study,
CERN-CEA collaboration – Steering committee -09 janvier 2015

44. WP7 : Mechanical studies of rutherford cable
CERN-CEA collaboration – Steering committee -09 janvier 2015

45. WP goals and deliverables
Deliverable (Dec. 2015): Finite Elements Model of cable samples lifecycle Steps: 1| Identification of several types of cables of interest for CEA and CERN (SMC, FRESCA2…). For each type of cable: 2| Identification of the strand(s) behaviour law 3| Modeling of the cabling process → validation on the base of tomographic analysis 4| Geometrical reconstruction of insulated cables 5| Modeling of the cable under mechanical solliciation → comparison with experimental results on stacks
CERN-CEA collaboration – Steering committee -09 janvier 2015

46. 2 mechanical models / 3 cable geometries
① Cable forming
With major simplifications (≠ CERN approach)
② Cable in service
Stack test modeling.
Standby, waiting for a postoc (Feb. 2015?)
CERN-CEA collaboration – Steering committee -09 janvier 2015

47. Samples inventory
9-strand cable: NbTi strand from Iseult magnet => setup model Tomographic and mechanical data already available 18- and 40-strand cable: Nb3Sn, Ø 1 mm strands PIT, RRP or copper Reacted or not Data is currently being collected
CERN-CEA collaboration – Steering committee -09 janvier 2015

48. On-going: mechanical characterization
Work performed by MSSMAT Monotone traction up to rupture Traction with load/unload cycles No cycling => Behaviour laws for ‘cable in service’ model ②
unreacted
reacted
strand alone (no cable) Ø 1 mm
copper
COCA/IRFU/S/CUXX
RRP
COCA/IRFU/S/RRPXX
10 m delivered to ECP (2013)
1 m under reaction
PIT
COCA/IRFU/S/PITXX
1.5 m delivered to ECP (07/2014)
CERN-CEA collaboration – Steering committee -09 janvier 2015

49. On-going: tomography and SEM
SEM on strands (reacted or not)
Tomography on cables (reacted or not)
Geometrical data for validation of the ‘cable forming’ model ①
CERN-CEA collaboration – Steering committee -09 janvier 2015

50. Status
2014 status Little modeling progress in 2014 due to lack of resource Delay in hiring a postdoc (5 shortlisted candidates; expected start: Feb./March 2015) Collection of raw data that will serve for the postoc Interaction with CERN Exchanges with CERN should be resumed on a regular basis Copper strand from CERN would be useful (10 m?) if available Maybe some more samples (TBC)
CERN-CEA collaboration – Steering committee -09 janvier 2015

51. Conclusions
CERN-CEA collaboration – Steering committee -09 janvier 2015

52. Merci pour votre attention !
Conclusions
Le respect du planning , en particulier pour Q4 (HL-LHC) et pour le dipôle FRESCA2 doivent rester notre priorité absolue. En particulier, 3 embauches (1 Ingénieur projet et 1 technicien bobinage et 1 projeteur) sont prévues pour Q4.
La collaboration se fait dans un très bon esprit. Il nous faut maintenir et renforcer ce bon climat
Merci pour votre attention !
CERN-CEA collaboration – Steering committee -09 janvier 2015