1. Analytical Cost Model (16 T dipole)
T. Martínez, J. Munilla, F. Toral - CIEMAT
Status of the project- February 2017

2. Preliminary main cost drivers
Manufacturing of main components (strict fabrication tolerances):
End spacers
Cu-Alloy wedges
Iron yoke laminations
Iron pads laminations
Master keys
Conductor and wedges insulation
Impregnation
Ground insulation
Plasma coating insulation
Aluminum shell
Axial rods
End plates
Quench Heaters 2

3. Status of the analytical study
End Spacers:
Raw material: 316L
Production process: 3D printing
Reference price (11T): 1.100€ (end saddle)+4.200€=5.300€ per coil
Estimation for 16T :
Inner layers: 5.300× =4.417€
Outer layers: 5.300× 103,8 60 =9.169€
2 coils and 2 apertures: € per magnet
High price: another alternative must be considered
Scaling by volume 3

4. Status of the analytical study
End Spacers:
Suggestion from CERN main workshop:
Consider another material for fast machining
No excessive grain growth during heat treatment
Non magnet
Fulfil mechanical/structural specifications
Stefano Sgobba will be contacted for recommendations
Couple of tons of test melt will be requested to a steel company (to be discussed/budget??) 4

5. Status of the analytical study
Cu-Alloy Wedges:
Raw material: CEP DISCUP C3/30
Production process: extrusion
Initial assumption: consider just 2 different wedge profiles instead of the real 10 different ones
One dipole cold mass contains approximately 560 meters of copper wedges of each different profile. The wedges shall be delivered in 3500 mm long pieces. Consequently in one cold mass there are 160 copper wedges pieces of each profile (considering initial assumption). 5

6. Status of the analytical study
Cu-Alloy Wedges:
Quotation for these 2 wedges profiles has been asked to Luvata and Buntmetall:
Wedge 10
Wedge 6
Wedge 10
Wedge 6 6

7. Status of the analytical study
Cu-Alloy Wedges:
Luvata proposal:
Half length: 1750 mm long pieces
Manufacturing tolerances change (+/-20 µm fabrication tolerances requested)
thickness +/- 0,03 mm
width +0,04 /-0,06  mm
First cost estimation:
Tooling: 1.500€ per profile
Material: €/kg (not confirmed)
Budget: 520kg x 90 €/kg= € per magnet
COST DRIVER!!
Note: due to the very different geometries of the profiles a more accurate estimation will come up from the evaluation of the 10 different profiles 7

8. Status of the analytical study
Cu-Alloy Wedges:
Our estimation basis on second Luvata’s figures:
520 kg of material per magnet
Cost estimation (considering 10 different profiles):
Tooling: x 10= € per 10 wedge profiles (life cycle of tooling?/price of maintenance?)
COST DRIVER
Mat.
Area mm2
quantity 1 dipole mass pcs
length mm
quantity 1 dipole mass meter
kg/m
quantity 1 dipole mass kg
Luvata's quotation Price EUR/Kg
Price EUR
Wedge 6
62,32 64
1.750
112
0,56 63
130
8130,12
Wedge 10 20
0,18
250
5017,60
Wedge 1
43,77
0,39 44
140
6149,37
Wedge 2
39,55
0,35 40
180
7144,06
Wedge 3
47,62
0,43 48
6690,27
Wedge 4
49,54
0,44 50
150
7457,16
Wedge 5
41,95
0,38 42
6314,65
Wedge 7
78,27
0,70 79
120
9425,46
Wedge 8
51,24
0,46 51
6684,65
Wedge 9
83,97
0,75 84
10111,87
518,23
mm2
520
73125
€/magnet 8

9. Status of the analytical study
Cu-Alloy Wedges:
On December 15th:Meeting at CIEMAT facilities with Ilppo Hiekkanen from Luvata
Luvata did not realize the real scale of the project
No commercial capacity for getting that amount of raw material
Assure lower prices for a very long series
Luvata proposses a meeting among the parts: CEP (raw material supplier), LUVATA, CERN and CIEMAT (comment with Daniel …too early for this kind of meeting)
Material properties: The minimum specification for the moment is that the tensile strength Rp0.2 should be larger 200 MPa after heat treatment to 650C. Good mechanical properties and a large RRR are an advantage. 9

10. Status of the analytical study
Cu-Alloy Wedges:
Buntmetall response:
Equipment of hydrostatic pressure does not allow them to use CEP DISCUP C3/30 (CEP DISCP-powder metallurgical process and Buntmetal alloys- melting&casting )
Another alternative under development:
Our requirement: Yield strength of 200MPa after a heat treatment at 650°C
Information requested by the company:
dwell time at 650°C: 10 hours?
the required electrical conductivity? (to be discussed)
Buntmetal starts a direct collaboration with Daniel (They want to do the development of the wedges and they will send him an offer for first parts, which CERN can then characterize) 10

11. Status of the analytical study
Cu-Alloy Wedges:
Another possible contact for the wedges fabrication could be: (contact provided by Spanish Industrial Liaison Office at CERN) –not contacted yet
INDUSTA
Polígono Industrial  Nº III. C/ Palmera nº Moncada (Valencia).
Contact person: Fernando Tatay
Telf
mvl: 11

12. Status of the analytical study
Plasma Coating Insulation:
2000€ per set of 14 parts for the plasma coating of the MQXF (1 coil)
Scaling by areas as Etienne Rochepault has suggested:
MQXF aperture: 150 mm
Dipole/quadrupole:
4 layers/2 layers
2 coils per magnet
2 apertures
Final price: € per magnet
Is it possible another kind of insulation for the end spacers? (cheaper)
CERN main workshop suggested to contact vacuum group
1/3 x2 x2 x2 x2 12

13. Status of the analytical study
Iron yoke and iron pad laminations:
Raw Material: ARMCO
Production process: Fine blanking
Manufacturing tolerances to be decided
Which is the optimum thickness to reduce the cost?
Laminations of 5,8 mm could be a good starting point
Optimum thickness advice has been requested to BNL contact (C. Manning November 4th-not reply)-contact provided by AK Steel people
Calculation of press size will be done
Feintool will be contacted 13

14. Status of the analytical study
Iron yoke and iron pad laminations:
VoestAlpine contact: Timothy Keppert He is an expert of steel and can provide always good recommendations on the selection of the material. However, before contacting Tim Daniel suggests to have a word with Etienne, who is in contact with Tim to select the best suited iron/steel for the collars.
After understanding the raw material constraints it would good to contact stamping companies like AMV and also start a study on the cost of stamping with the CERN main workshop (Daniel’s suggestion).
Elay has been contacted: Meeting at Ciemat facilities on December 20th (budget sent???-information from ELAY)
Spanish company involved in:
ARMCO laminations for XFEL project
Other projects for CERN??? 14

15. Status of the analytical study
Conductor and Wedges Insulation:
Experts form CERN has been contacted (they are working on some figures)
Impregnation:
CTD-101K will be used
Price will be required
Confirmation regarding resin volume needed (25% of coil volume) has been requested to the 927 workshop (Nicolas Bourcey)
Confirmation regarding resin volume needed (25% of coil volume) has been requested also to Helene Felice, Damien Simon and Clement Lorin (answered by Clement: I would say that a value between 25%-33% seems realistic depending on your cable size versus insulation thickness).
Daniel’s suggestion: This scaling could be checked and compared with 11 T dipole experience. Remy Gauthier and Sebastien Clement are good contacts. 15

16. Status of the analytical study
Ground insulation: price for Kapton HN 125µm has been required (Isovolta)
(500 km length/ 250 mm width)
Rough cost estimation for 127µm film x250 mm width: 10,31€/ m
866€/magnet as 6 layers of polyamide are foreseen. 16

17. Status of the analytical study
Aluminum shell:
Raw Material: Al alloy
Outer diameter: 820mm
Thickness: 100 mm
Maximum length?
Extrusion press for this size available ?
Laurent Deparis will be contacted.
Contact provided by Spanish Industrial Liaison Office at CERN: (not contacted yet)
Euskal Forging:
Josu Ortego
Deputy Head of Sales
Grupo Euskal Forging
Mobile:
Tel.:
Fax: 17

18. Status of the analytical study
Axial rods and End plates will be calculated using Fernando’s tool
(not identified as main cost drivers) 18