1. TQS Overview and recent progress
Shlomo Caspi
LBNL, November

2. Outline Analysis – magnetic, structural
Magnet Program Goals and status
TQS01 concept – shell, keys, rods
Magnet Production
Analysis – magnetic, structural
Magnet test results
Summary
TQ Review - November 29-31, 2006

3. LARP Magnet Program Goals (LHC Accelerator Research Program)
Long term goal:
“Demonstrate by 2009 that Nb3Sn magnets are a viable choice for an LHC IR upgrade”
Short term goals:
Build 1-m long, 90-mm bore Nb3Sn quadrupoles.
Compare performance with the design expectation.
Compare two structures
TQS01 - Aluminum shell-based
TQC01 - Collar-based
TQ Review - November 29-31, 2006

4. Pre-Feb 2006 review Work Plan, Distribution, and Schedule:
Design of cable, coil, and tooling: FNAL+LBNL (Feb. 2005)
Fabricate/Insulate cable: LBNL
Design and Procure coil fabrication tooling/parts: FNAL
Design and fabricate TQS01 structure LBNL
Fabricate, React, Impreg. Practice coils (CW-01,02,03,04): FNAL+LBNL
Fabricate, React, Impreg TQS01 coils (CW-05,06,07,08): FNAL+LBNL
Assemble and tested practice coils and structure LBNL
TQ Review - November 29-31, 2006

5. Post-Feb 2006 review
Work Plan, Distribution, and Schedule (Pre-Feb 2006 review):
TQS01 Final Assembly LBNL (March 06)
TQS01 Test LBNL (April-May 06)
TQS01 Data reduction and post analysis LBNL
TQS01b Final Assembly LBNL (October 06)
TQS01b Test LBNL (November 06)
TQS01b Data reduction and post analysis LBNL
Fabricate, React, Impreg. 4 TQC01 coils FNAL+LBNL
Fabricate, React, Impreg. 2 spare coils FNAL+LBNL
Fabricate, React, Impreg. 4 TQC02 coil FNAL+LBNL
Fabricate 2 TQS02 coils FNAL+LBNL
Fabricate, React, Impreg. 2 TQS02 coils FNAL+LBNL
TQ Review - November 29-31, 2006

6. High gradient (> 200 T/m) in 90 mm aperture Nb3Sn superconductor
The Magnet Challenge
High gradient (> 200 T/m) in 90 mm aperture
Nb3Sn superconductor
Azimuthal Stress – 150MPa
Axial Force – 350kN
TQ Review - November 29-31, 2006

7. Strand and Cable Unit Layer 1 Layer 2 STRAND Type MJR Diameter mm 0.7
Cu/Sc
0.89
Jsc (4.2 K, 12 T)
A/mm2
1950
CABLE
N strands 27
Mid-thickness bare
1.26± 0.01
Width bare
10.03± 0.05
Keystone angle
Degree
1.0± 0.1
Insulation thickness
0.125
TQ Review - November 29-31, 2006

8. Coil and Structure (friction based)
Unit
Layer 1
Layer 2
Turns per block
6/12 16
Mandrel diameter mm 90
Shell thickness 22
Shell outer diameter
500
OPERATING EXPECTATIONS at 4.5 K (1.9 K):
Short sample current kA
12.1 (13.2)
Peak conductor field (2D) T
11.06 (11.96)
9.42 ( )
Gss
T/m
217 ( 234 )
Stored energy
kJ/m
392 ( 436 )
Applied Coil azimuthal stress warm
MPa 33 34
Applied Coil azimuthal stress cold
125
130
Lorentz Stress (azimuthal)
-113 ( -135 )
-77 ( -91 )
Axial force all coils (same as Lorentz) kN
+90 ( +107 )
+241 ( +287 )
Average axial stress (contact area with end plate)
48 ( 57 )
TQ Review - November 29-31, 2006

9. TQS01 – shell, keys, rods No collars – islands attached to coil
Bladders for coil azimuthal pre-stress.
Piston for coil axial pre-stress.
Low RT assembly pre-stress.
High Cold assembly pre-stress.
TQ Review - November 29-31, 2006

10. TQS01 – Aluminum shell Key and bladder assembly
2 layers
Filler
Keys
4 pads
Bladder
Yoke
Aluminum shell
TQ Review - November 29-31, 2006

11. End Plate and Rods Axial Aluminum rods
TQ Review - November 29-31, 2006

12. Magnet Production Coil winding and binding Coil reaction
Coil instrumentation
Coil impregnation
Coil-pack sub-assembly
Yoke-shell sub-assembly
Final assembly
TQ Review - November 29-31, 2006

13. Coils Received from FNAL
Winding and Binding
Coils Received from FNAL
TQ Review - November 29-31, 2006

14. Coils Wind React Impregnate 72 hr at 210 C 48 hr at 400 C
TQ Review - November 29-31, 2006

15. Coil pack – coils and pads Structure pack – shell an yoke
Final assembly
Coil pack – coils and pads
Structure pack – shell an yoke
TQ Review - November 29-31, 2006

16. Axial Rods Assembly
TQ Review - November 29-31, 2006

17. End Plates and axial rods
TQ Review - November 29-31, 2006

18. Azimuthal pre-stress (bladder operation)
TQ Review - November 29-31, 2006

19. Coil - Instrumentation
Strain gauges placed on layer 1 island
Voltage tap
Strain gauge
Inner layer trace
TQ Review - November 29-31, 2006

20. Instrumentation -Trace
Voltage taps
Strain Gauge
Heater
TQ Review - November 29-31, 2006

21. Shell - Instrumentation
TQ Review - November 29-31, 2006

22. Axial Aluminum rods (44 mm dia.)
Rods - Instrumentation
bullets
End plate (89 mm thick)
Axial Aluminum rods (44 mm dia.)
Strain gauges
TQ Review - November 29-31, 2006

23. Analysis
Magnetic
Structural

24. Integrated design and analysis
FEM structure multi-physics
CAD (engineering)
Axial pre-load
Azimuthal pre-load
Cool-down
Excitation
FEM (magnetic)
TQ Review - November 29-31, 2006

25. TOSCA I=13.2kA,1.9K Layer 2 |B|=11.8 T END Layer 1 |B|=11.96 T in SS
Maximum field:
Layer 1 - straight section
Layer 2 - end
TQ Review - November 29-31, 2006

26. Peak field in the conductor
TQ Review - November 29-31, 2006

27. ANSYS model – straight section
Rule 1 - No azimuthal separation at the pole 1 2 3
TQ Review - November 29-31, 2006

28. ANSYS model – coil ends Island End-shoe Spacer
Rule 2 - No axial separation between island, spacer, end-shoe and coil blocks
TQ Review - November 29-31, 2006

29. Assembly Procedure Cool-down Coil pack snug inside structure
Axial pre-compression: 250 kN/end
Azimuthal coil pre-compression: MPa
Cool-down
A factor ~3 gain in applied axial compression
A gain of ~150 MPa in azimuthal compression
TQ Review - November 29-31, 2006

30. Calculated load Steps Step 1 - Load axial rods
Step 2 - Azimuthal coil pre-stress (bladder and key)
Step 3 - Cool-down
Step 4 – Excitation
TQ Review - November 29-31, 2006

31. Coil average azimuthal stress (layer 1) (with friction)
Short sample 4.2K
Short sample 1.9K
Pole unloading
Mid-plane loading
TQ Review - November 29-31, 2006

32. Axial displacement - solid pole (with friction)
Island displacement
TQ Review - November 29-31, 2006

33. Lorentz axial force 331/395 (kN) Applied axial force 800 (kN)
Axial Lorentz Force
Lorentz axial force 331/395 (kN)
Applied axial force 800 (kN)
(with friction)
TQ Review - November 29-31, 2006

34. Layer 1 end gaps (0.2 friction)
Gap opens as the island slides axially due to azimuthal Lorentz forces
Short sample 4.2K
Short sample 1.9K
Pole separation
TQ Review - November 29-31, 2006

35. TQ Review - November 29-31, 2006

36. Impact of island gaps on axial strain
Coil
Wedge
Coil
Island cut
TQ Review - November 29-31, 2006

37. Test
TQ Review - November 29-31, 2006

38. TQS01 – K Performance
TQ Review - November 29-31, 2006

39. TQS01/01b – K Performance
TQ Review - November 29-31, 2006

40. TQS01/01b: Quench-Origin Comparison
1,4,5
Ramp 1
TQS01
Plateau
Ramp
TQS01b
Plateau 1
TQ Review - November 29-31, 2006

41. Shell Stress Warm-up (Partial) Cool-down Training Assembly ~210 K
TQ Review - November 29-31, 2006

42. Rod Stress Assembly Cool-down Training Warm-up (Partial)
TQ Review - November 29-31, 2006

43. Island Stress Cool-down Assembly Training Warm-up (Partial)
TQ Review - November 29-31, 2006

44. Summary Low assembly pre-stress
Substantial pre-stress gain during cool-down
TQS01– started training at 80% of short sample reach 87% plateau on the 12’th quench.
TQS01b – started training at 75% of short sample reach 82% plateau on the 7’th quench.
Analysis and expectations - measurements and confirmation
Low plateau – issues near the island gaps
TQ Review - November 29-31, 2006

45. LBNL SUPERCONDUCTING MAGNET GROUP
Paul Bish
Shlomo Caspi
Dan Cheng
Dan Dietderich
Paolo Ferracin
Arno Godeke
Ray Hafalia
Roy Hannaford
Sharon Hernandez
Hugh Higley
Daryl Horler
Chip Kozy
Al Lietzke
Nate Liggins
Juan Lizarazo
Al McInturff
Marco Monroy
Mark Nyman
Dee Pickett
Gary Ritchie
Glenna Rogers
GianLuca Sabbi
Jim Smithwick
Jim Swanson
TQ Review - November 29-31, 2006