2. Wideband kickers Mechanical design and Fabrication
Eric Montesinos, Sébastien Calvo
on behalf of all teams involved
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva

3. Outlook Resources and Timeline Strip Line Kickers Slot Line kicker
Conclusion
Strip Line Kickers
Slot Line kicker
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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4. Resources and Timeline
2014
2015
2016
2017
2018
Débora Aguilera
Strip Line kicker
EM simulations
Mechanical Design
1 Prototype Fabrication
1 Prototype Installation SPS
2 + 1 Series Fabrication
2 Series Installation in SPS
1 Spare in Lab
Sébastien, Jean, Jarmo, Débora, and the two first Strip Line Kickers installed in the SPS
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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5. Resources and Timeline
2014
2015
2016
2017
2018
Débora Aguilera
Irene Alonso
Strip Line kicker
Slot Line
Slot Line kicker
Preliminary studies
EM simulations
Mechanical Design
Prototype for lab measurements (atmospheric)
Prototype for lab measurements (vacuum)
1 + 1 Series Fabrication
1 Installation in SPS during YETS
1 spare in Lab
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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6. Strip Line Kickers, Mechanical design, Fabrication & Installation
Alignment system
Pumping port
shielding
Specific bellow
Kickers
Kickers
Standard bellow
Vacuum pipe at the size of the future Slot line Kicker
Alignment system
Supporting system
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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7. Strip Line Kickers, Mechanical design, Fabrication & Installation
Feedthroughs
(Kovar)
Body
(Stainless Steel)
Electrodes
(Cu OFE)
Strip Line Kicker
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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8. Strip Line Kickers, Mechanical design, Fabrication & Installation: Feedthroughs
Five suppliers were contacted
Kyocera
SST
MDC vacuum products
Neyco
SCT
It took more than ten months to receive, test and qualify the feedthroughs
Temperature test
Temperature shock test (water bath & heat gun)
Traction and compression test
Vacuum leak test
Only Kyocera was qualified
7/16 DIN connector
(preferred)
Offers were rejected by the companies due to an inability to reach the initial requirements
50 Ω
0 – 1 GHz
5 kW
DN 40 CF flange
Conical shape
Final diameter 5 mm
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9. Strip Line Kickers, Mechanical design, Fabrication & Installation: Feedthroughs
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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10. Strip Line Kickers, Mechanical design, Fabrication & Installation: Electrodes
Specific shape provided by simulations
Copper OFE for high thermal conductivity
Machined from a massive copper block due to the complex shape
Conical shape of the feedthrough, smooth transition to avoid sharp edge at the point where the feedthrough joins the electrode
Cu OFE electrode
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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11. Tooling system for electro polishing
Strip Line Kickers, Mechanical design, Fabrication & Installation: Body
All in one machined, including two vacuum chamber flanges and four feedthrough ports
316LN 3D forged stainless steel for good vacuum knives
Vacuum leak tested
(less than 1 x mbar l / s)
Electro polishing to improve inner surface finish (including tooling)
Strip Line kicker Body
Tooling system for electro polishing
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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12. Strip Line Kickers, Mechanical design, Fabrication & Installation
The two strip line kickers installed in the SPS
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13. Strip Line Kickers, Mechanical design, Fabrication & Installation: conclusion
Many processes have been qualified, that will all be useful for the next slot line kickers
Isolated and universal regardless the orientation supports
Specific supporting system to allow individual alignment, with one parallel support, two intermediate supports, two adaptors and three feet
Body machined such that a Taylor Hobson sphere can be adapted to allow an easy positioning of the kickers (position of electrodes in reference to Taylor Hobson spheres)
RF wire test, including the construction of all the necessary tooling
Peripheral items constructed, pumping port shielding, bellows, enamelled flanges, vacuum chambers,…
Qualification processes conducted, metrology, cleaning, outgassing analysis, vacuum leak detection, residual gas analysis, aperture and impedance simulations (horizontal/vertical)
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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14. Slot Line Kickers, Mechanical design, Fabrication & Installation
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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15. Slot Line Kickers, Mechanical design, Fabrication & Installation
90º step transition
We did several initial studies including
90º step transition
Lateral feedthroughs
90º tapered transition (preferred one from mechanical point of view)
90º tapered transition
Lateral feedthroughs
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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16. Slot Line Kickers, Mechanical design, Fabrication & Installation
Feedthroughs
(Copper)
Top cover
(316 Ln)
Electrode
(Cu OFE)
Spacers
(Shapal®)
Body
(316 Ln)
SPS vacuum
DN159 flange
Supporting system
Weight 367 kg
Length 1422 mm
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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17. Slot Line Kickers, Mechanical design, Fabrication & Installation
The kicker was designed with
One body
two half shells EBW
two SPS flanges TIG welded
Two vacuum seals
Two covers
Two electrodes
2 x four Shapal® spacers
Four feedthroughs
Sketch of the slot line kicker
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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18. Slot Line Kickers, Body
The body was found very difficult to be built in one single item
We decided to built it by two half shells
It includes vacuum CF knife and RF contact
For those reasons it will be made in Stainless Steal 316 Ln
The two half Shells will be EBW (mock-ups under construction to prove the feasibility, internal roughness induced by EBW, tilt over a length of 1.5 meter !)
Two half shells with openings
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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19. Slot Line Kickers, Body
Outgassing holes along the RF contact
The body was found very difficult to be built in one single item
We decided to built it by two half shells
It includes vacuum CF knife and RF contact
For those reasons it will be made in Stainless Steal 316 Ln
The two half Shells will be EBW (mock-ups under construction to prove the feasibility, internal roughness induced by EBW, tilt over a length of 1.5 meter !)
RF contact and CF knife
EBW fully penetrant for internal roughness test
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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20. Slot Line Kickers, Body
EBW body and CF flanges
With the EBW body, we will add two standard SPS vacuum flanges
Those will be TIG welded from the internal surface by hands (too complex geometry for an automated EBW)
We also designed a copper seal, it is laser cut from a copper sheet
Fully welded body
and
Copper seal
RF contact
and
CF knife + copper seal
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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21. Slot Line Kickers, Covers, Feedthroughs
We designed the covers as we designed the body, with CF knife
Toon Roggen did thermal simulations that showed the feedthroughs must extract quite some heat
The feedthroughs are the ones we designed for the strip line kicker, except the inner line that is in plain copper to help removing the heat load
(six feedthroughs were already delivered to cern and were vacuum leak tested)
Two covers
Thermal simulation of the feedthroughs, left in stainless steel, too hot, middle in copper, ok, right sketch of the feedthrough
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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22. Slot Line Kickers, Electrodes
Cu OFE electrode
The electrode will be machined from a massive piece of Cu OFE
There will be four Shapal® spacers that will ensure two functions
Mechanical positioning of the electrode
Thermal bridge to the cover
Shapal® spacers
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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23. Slot Line Kickers, Electrodes
Taking into account the experience with the strip line kicker a supporting system that also allows alignment has been designed
On request, it could easily be isolated by simple foil of Kapton®
Due to the weight of the overall system (367 kg) a specific transport tool is also under study
Supporting system
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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24. Slot Line Kickers, next steps
2014
2015
2016
2017
2018
Slot Line
Slot Line kicker
Preliminary studies
EM simulations
Mechanical Design
Prototype for lab measurements (atmospheric)
Prototype for lab measurements (vacuum)
1 + 1 Series Fabrication
1 Installation in SPS during YETS
1 spare in Lab
LIU-SPS Wideband Feedback Review, September 2016, CERN, Geneva
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25. Conclusion: on track
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