1. High Order correctors coil manufacturing
Marco Statera
on behalf of the LASA team
CERN 20/4/2016

2. SUMMARY ground insulation test coils and 6pole coils
coils after a cooldown cycle
20/4/2016
M. Statera

3. GROUND INSULATION: COILS
measured in a single point
up to 5 kV
impedance
[TW] S1
1.66 S2
1.75 S3
1.95 S4
1.36 S5
0.765 S6
1.50
TC5
1.77
20/4/2016
M. Statera

4. GROUND INSULATION: 6POLE
VOLTAGE
ASSEMBLY
LOW TEMPERATURE
(16-19/2 test)
ROOM TEMPERATURE no
return flux
insulation
after welding
N2 G
90 K
He L
HE G
24 K
after the test
no return flux – connections side
250 V
18.6 GW
93 GW
500 MW
17.8 GW
500 V
113 GW
1.97 GW
940 MW
960 MW
250 MW
7.3 GW
1000 V
124 GW
1.14 GW
1.02 GW
555 MW
2000 V
120 GW
1.01 GW
20/4/2016
M. Statera

5. HIGH VOLTAGE INSULATION
G10 wires-iron stainless steel support
PFTE tubes wires-stainless steel support
20/4/2016
M. Statera

6. WIRES INPUT - OUTPUT stainless steel spacer stainless steel ring G10
20/4/2016
M. Statera

7. KAPTON® INSULATION
2 kV
20/4/2016
M. Statera

8. BUS BAR CONNECTION
0.3 mm G10
20/4/2016
M. Statera

9. CONCLUSIONS each coil tested @ 5 kV
sextupole tested during installation, at low temperature and again at room temperatuture
the electrical connections circuit and connection have to be optimized
20/4/2016
M. Statera

10. TESTED COILS TC4 G10 TC5 ULTEM™ TC6 DURATRON© S8 G10 20/4/2016
M. Statera

11. TESTED COILS material windings dimensions mm x mm TC4 G10 204 88 x 126
ULTEM™
174
TC6
DURATRON©
170
88 x 132 S8
216
20/4/2016
M. Statera

12. G10 COILS mechanical properties minimun thickness machinable TC4 S8
S2 tape filling
TC4
mechanical properties
minimun thickness
machinable
0.2 mm G10
inner 0.2 mm G10
G mm
outer 0.2 mm G10 S8
S2 tape and G10 are placed after the winding
20/4/2016
M. Statera

13. ULTEM™ COILS 1.2 mm 1.2 mm 3D printed shape on demand 3D structure
resin penetration
20/4/2016
M. Statera

14. DURATRON© COILS bulk machinable mechanical properties 1.3 mm 1.3 mm
20/4/2016
M. Statera
1 mm mm

15. TECHNOLOGIES PRO’S CON’S G10 glass epoxy laminate
mechanical propertiess
minimum thickness
machinable
radiation hardness
ULTEM™
polyetherimide
(PEI)
3D printed
shape on demand
3D structure
resin penetration
low mech properties
print time
min thickness
DURATRON©
PEI-
30% glass fiber
easy machining
mechanical propertiess
high cost
BTS2
by Arisawa
Bismaleimide-
Triazine resin – S2 laminate
(less easy than G10)
thin foils
mechanical properties
same technology as G10
very high cost
20/4/2016
M. Statera

16. TRAINING TC4
4.2 K
2.5 K
20/4/2016
M. Statera

17. TRAINING TC5 ULTEM™ training not negligible 4.2 K 2.2 K 20/4/2016
M. Statera

18. TRAINING TC6 DURATRON©
no training
4.2 K
2.2 K
20/4/2016
M. Statera

19. TRAINING S8
no training
4.2 K
2.2 K
20/4/2016
M. Statera

20. TRAINING OVERVIEW
I/IC
20/4/2016
M. Statera

21. TRAINING OVERVIEW 2 temperature 4.22 K temperature 2.17 K Bmx [T]
on coil IC
Imx/IC
Bmx[T]
TC4
2.909
289.95
0.907
3.7683
375.58 K
TC5
2.752
302.41
0.990
3.5664
391.95
0.944
TC6
2.620
313.47
0.948
3.3985
406.39
0.906 S8
2.923
288.87
0.962
3.7859
374.21
0.925
20/4/2016
M. Statera

22. DID THE COILS SURVIVED? TC4 ok TC5 ULTEM™ damaged
G10 technology commissioned
TC5 ULTEM™ damaged
low modulus
TC6 DURATRON© small defects
epoxy delamination (thin layer)
small cracks in bulk epoxy
S8 ok
cracks on heater
20/4/2016
M. Statera

23. WINDING QUALITY TC5 ULTEM™ TC6 DURATRON© @CERN @LASA edms n. 1554721
M. Crouvizier S. Sgobba
TC6 DURATRON©
@LASA
D. Pedrini A D C B E F H G
20/4/2016
M. Statera

24. TC5 TRANSVERSE CUTS dimensions not optimized
quite symmetric arrangement
dimensions not optimized
outer resin thickness
(coil specific)
cracks
perpendicular to surface
stops in the area between Ultem™ and glass fiber surrounding the wires
20/4/2016
M. Statera

25. TC5 LONGITUDINAL CUTS cracks no cracks between wires
perpendicular to surface
through Ultem and resin
stops in the area between Ultem and glass fiber surrounding the wires
no cracks between wires
epoxy-Ultem detaching in some spots L3 L2
20/4/2016
M. Statera

26. TC6 DURATRON© STRAIGHT thin section (few mm) stacking not perfect
no resin detaching
1 void wires-duratron
stacking not perfect
inner dimension not optimized
duratron deformation during impregnation C H
20/4/2016
M. Statera

27. TC6 DURATRON© BEND some voids one crack appeared after 2 days
LEICA stereoscope
some voids
impregnation to be improved
one crack appeared after 2 days
stress release
no epoxy detaching
20/4/2016
M. Statera

28. HOW DID THE COILS PERFORM?
all coils showed good maximum current
G10
good performance
low radiation hardness
ULTEM™
training
did not survive the cooldown
DURATRON©
adhesion to be crosschecked
BTS2
same technology as G10
the resin adhesion still not tested
NEXT STEPS
resin adhesion test
octupole coils: DURATRON©
material is in house
decapole coils: BTS2
material ordered
the mechanical and electromagnetic design can be fit to both materials
20/4/2016
M. Statera

29. TENSILE SHEAR STRENGTH
compare the CTD101K adhesion
G10
DURATRON©
BTS2
glued area: 4 mm x 15 mm
inspired to tensile shear test
ISO 4587: Adhesives -- Determination of tensile lap-shear strength of rigid-to-rigid bonded assemblies
ASTM D : Standard Test Method for Strength Properties of Adhesives in Shear by Tension Loading of Single-Lap-Joint Laminated Assemblies
The BTS2 material to prepare the specimens is kindly supplied by Dr Nakamoto and his team at KEK
Some material is still available: it may be used for other tests, to be agreed with Dr Nakamoto
20/4/2016
M. Statera

30. SPECIMENS room temperature tests 1 G10, 2 DURATRON© and 2 BTS2
cooled at 77 K and then tested at room temperature
2 DURATRON© and 2 BTS2
specimens ready to be glued
20/4/2016
M. Statera

31. CONCLUSIONS each coil tested @ 5 kV
sextupole tested during installation, at low temeprature and again at room temperatuture
the electrical connections circuit and connection have to be optimized
two coils’ construction technologies tested
compared to G10 coils
3D printed ULTEM™ not suitable
bulk DURATRON© coils will be installed in the octupole
BTS2 instead of G10
resin adhesion will be tested soon
to be installed in decapole
adhesion test to compare G10, DURATRON© and BTS2
in preparation
20/4/2016
M. Statera