1. LCLS Vacuum System Plans (July 07)
5/25/2019
LCLS Vacuum System Plans (July 07)
Lehman Review
July 10th-12th
2007
Test

2. Aluminum Extrusion (Primary Design)
Prototyping - started in earnest after the last Lehman Review in November 06
Emil Trakhtenberg - Responsible for development so far : see Feb 22nd report – “Aluminum Extrusion as an Option for LCLS Undulator Vacuum Chamber” and PAC 07 paper “A Study of the minimum wall Thickness for an extruded Aluminum Vacuum Chamber”
>50 full length extrusions at ANL – Surface finish achievable ~ nm so far.
Surface finish development running in parallel with full length machining
Machining and welding on short samples – full length prototype by mid August
July 07
Pat Den Hartog (APS) – Responsible for production of Chambers
Greg Wiemerslage - Production Engineering
Mark Erdman Quality Engineering - Specs, Procedures & Docs
Joe Gagliano Welding and Vacuum system assembly

3. >50 full length extrusions at ANL

4. Full Length Prototype highlights:
AL Extrusion Schedule
Full Length Prototype highlights:
Existing surface finish : nm
Polished samples arriving now - 3 more leaving ANL for EFC now. Expect 2nd iteration results by 7/30/07
Citrinox cleaning has little or no effect
Surface finish degradation of
Full length Chamber with 0.5mm -
Fully machined chamber ~7/25/07
Welding, cleaning, baking and vacuum testing ~ mid August 07
Prototype evaluation complete by end of August 07

5. Early AL Extrusion Prototype results

6. AL Extrusion Production Schedule
QA chambers first five 12/4/07 12/6/07
Pre-cleaning of first five 12/7/07 12/7/07
Weld prep, weld and leak check first five 12/10/07 12/14/07
Post cleaning first five 12/12/07 12/17/07
Bake first five Chambers 12/14/07 12/20/07
Leak check and RGA first five /17/07 12/21/07
Ship first five chambers to SLAC 1/7/08 1/10/08
First Five Chambers at SLAC 1/7/08 1/10/08
(SS schedule 11/ /26)

9. AL Extrusion Production Schedule Estimate V’s Existing SS Vac Chamber Schedule
SS Vacuum Chamber Lot (A ) 10/26/07 12/26/07 (4) Ship to SLAC 1/2/08
AL Vacuum Chamber Lot (A ) (5) Ship to SLAC 1/10/08
SS Vacuum Chamber Lot (B ) 11/28/07 1/07/08 (7) Ship to SLAC 1/14/08
AL Vacuum Chamber Lot (B ) (5) Ship to SLAC 1/21/08
SS Vacuum Chamber Lot (C ) 1/02/ /31/08 (7) Ship to SLAC 2/7/08
AL Vacuum Chamber Lot (C) (12) Ship to SLAC 2/19/08
SS Vacuum Chamber Lot (D) 1/31/ /03/08 (7) Ship to SLAC 3/11/08
AL Vacuum Chamber Lot (D ) (12) Ship to SLAC 3/26/ Available
SS Vacuum Chamber Lot (E) 3/03/ /31/08 (8) Ship to SLAC 4/2/ Available
AL Vacuum Chamber Lot (E ) (12) Ship to SLAC 4/16/08 AL Spares
SS Vacuum Chamber Lot (S) 3/19/ /09/08 (4) Ship to SLAC 4/16/08 SS Spares

10. AL Extrusion Costs Item Cost per Chamber Total Cost/40 Cost based on
$210.31
$8,412.51
actual order received(PO# 7a-02242)
Chamber Machining
$6,200
$248,000
first two articles from Hi-Tech $15k
Quote # from Metalex ea
bi-metallic flanges
$1,000
$40,000
Engineer's experience
attachment to strongback
$1,500
$60,000
based on quote
surface finish improve
1500 for abrasive flow or EP
based on early vendor consults
$3,000 if both are needed
$120,000
weld fixturing costs
$7,000
based on previous experience
shipment crating cost
Sub Total
$544,912.51

11. Engineer's estimate and experience 48 hours (no effort charged)
AL Extrusion Costs
Effort Item
Hours per chamber
Total hours/40
Cost Based on QA
4 hours
160
Engineer's estimate and experience
cleaning
8 hours
320
weld prep
2 hours 80
welding
3 hours
120
post weld leak check
post weld cleaning
bake-out prep
bake-out
48 hours (no effort charged)
1920
leak check and RGA
assemble strongbacks
shipping prep
Average Tec/Eng rate ~$100/hr
Total hours
1720
Sub Total
$17,200
Total Cost
$562,112.51

12. AL Extrusion plan achieves Cost and Schedule
Stainless Procurements
Alloy $115815
Side Wall $140600
End Cap $119621
Strongback – Machining $604321
Total Cost SS procurements $ (in procurement on hold)
Total Cost AL Extrusion $ (Estimate)
SS Vacuum Chamber Lot (A ) 10/26/07 12/26/07 (4) Ship to SLAC 1/2/08
AL Vacuum Chamber Lot (A ) (5) Ship to SLAC 1/10/08
AL Vacuum Chamber Lot (D ) (12) Ship to SLAC 3/26/ Available
SS Vacuum Chamber Lot (E) 3/03/ /31/08 (8) Ship to SLAC 4/2/ Available
for info on sharepoint

13. Copper tube Vacuum Chamber
Back-up Plan
Copper tube Vacuum Chamber

14. Copper Tube Prototype and Production (BACK-UP)
Prototype work starting now – drawings and materials
4 weeks for production of parts
2 weeks for assembly, bake-out and vacuum tests
Second Vacuum Shop Crew available:
John Hoyt Brazing and Vacuum system assembly
Evaluate end of August 07 with Extrusion

15. Revised Copper Chamber Design
The existing LCLS Vacuum group has quickly changed directions going from the Stainless Steel design to the Copper Chamber
The group is enthused to support the copper chamber.

16. Copper Tube Design from April 2004

17. Copper Tube Design from April 2004

18. Design Description
Copper Tube (alloy 110) drawn into the shape of a 12 mm X 5 mm (ID) oval
Flanges and mounting blocks are joined to the tube. The use of Ag-Sn-Cu solder has been successfully used on vacuum chambers in the past.
Tube is polished using singularly or in combination: electro-polish and abrasive flow machining (this is also being used on the aluminum extrusion).
The copper tube will be bolted to the strongback
The strongback is made of 6061 aluminum to reduce cost and effort.
The copper tube will use the same sputtering technique that was developed for the internal aluminum coating of the stainless steel chamber.
This assembly will be bakable to 150oC for beamline use.

19. Design Description
Copper Tube (alloy 101) drawn into the shape of a 5 mm (ID) X 6 mm round
Flanges and mounting blocks are joined to the tube. The use of Ag-Sn-Cu solder has been successfully used on vacuum chambers in the past.
Tube is polished using buffed drawing dies.
The copper tube will be bolted to the strongback
The strongback is made of 6061 aluminum to reduce cost and effort.
This assembly will be bakable to 150C for beamline use.

20. Copper Chamber Design 2007
Copper Chamber bolted to an aluminum strongback.

21. Copper Chamber Design
Piece parts have been reduced to drawings

22. Cost for Prototyping Total $10, 300
These are ANL Central Shops costs and schedule WITHOUT any polishing costs. That will be handled by the ANL team
This will not use an oval tube, a round tube is obtainable in 4 weeks for $750.
Prototype Schedule: 4 weeks to build parts
1-2 weeks for assembly and baking
Completion ~6 weeks

23. Round Tube Costing Prototype Tubing (2) Pieces will cost $750
Copper tubing vendor has stated in the past that they can improve the surface finish to a 12 in. They need more time to work this out.

24. Oval Tubing Cost Production Tubing
Copper tubing vendor has stated in the past that they can improve the surface finish to a 12 in. They need more time to work this out.
Total cost for 40 units= $6,680

25. Production Costs Vacuum factory work: Cleaning 4 units per day
The costs for the strongback, surface finish, and the flange weldments appear to be overstated at this point. As this develops, these costs will be updated.
Vacuum factory work:
Cleaning 4 units per day
Assembly units per day
Bake out - Leak Checking 3 units per week
Testing 2 units per day
Effort cost for 18 hours= $2,160 ea.
Piece Part Cost $8, Overall Cost $315,433

26. Production Schedule First Unit -Nov. 15
Last Unit for Installation- Mar. 15

27. Organization
Responsible Engineer is Soon-Hong Lee
Supporting Engineers are James Morgan and Dean Walters
Coating support technician is Guy Harris
Design support is Scott Doran
Brazing and Vacuum system assembly is John Hoyt + 3