1. Superconducting RF Cavity/Cryomodule Development at Fermilab (Industrialization) C.M. Ginsburg (FNAL) Proton Accelerators for Science and Innovation 2 nd Annual Meeting Rutherford Appleton Laboratory, UK 3-5.April 2013

2. Fermilab Overview  SRF activity at FNAL/ANL is in support of Project X, ILC, or other future SRF projects  Explicitly includes industrial development, and associated R&D for improved performance and reliability, and reduced cost  Infrastructure availability and personnel development permit the development of industrial partners for SRF cavities and cryomodules  FNAL philosophy: the laboratory does not duplicate activity or compete with industrial capability  Industry can provide most materials and services more quickly at lower cost  Exceptions involve substantial infrastructure, e.g., cryogenic systems  Most of the industrialization focus has been for the ILC, so this talk will be weighted toward ILC (electron) technology  Most conclusions are broadly applicable to other SRF projects ...Proton accelerators in particular 5.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop2 ANL/FNAL cavity processing & assembly facility  Located at ANL; designed and built jointly  ANL group Electropolishing (EP) of 1-cell and 9-cell ILC-style cavities  FNAL group high-pressure water rinse (HPR) tool  Cavity moves vertically, wand rotates  Cleanroom class 10, 100, 1000  Ultrasonic (US) rinse tank in anteroom  Cavity vacuum system

3. Fermilab Outline  Cavity vendor development  Cavity processing vendor development  Cavity and cryomodule value engineering  Cryomodule assembly  Not yet industrialized in the US; XFEL example will be instructive  Existing industrialization workshops (ILC) 5.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop3 ANL/FNAL cavity processing & assembly facility  Located at ANL; designed and built jointly  ANL group Electropolishing (EP) of 1-cell and 9-cell ILC-style cavities  FNAL group high-pressure water rinse (HPR) tool  Cavity moves vertically, wand rotates  Cleanroom class 10, 100, 1000  Ultrasonic (US) rinse tank in anteroom  Cavity vacuum system

4. Fermilab Bare cavity sequence Each inspection, processing and test step is recorded in an electronic traveler 4Ginsburg - NGLS Review Feb 5-8, 2013 5.Apr. 20134Ginsburg (FNAL) 2nd PASI Workshop For large projects like XFEL, it may make sense to dress cavities before vertical test

5. Fermilab Cavity dressing sequence 5.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop5

6. Fermilab CM assembly sequence (part 1) 5.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop6 Receive dressed cavities at CAF- MP9 Receive peripheral parts Assemble dressed Cavities to form a String in the Cavity String Assembly Area (Clean Room) Install String Assembly to Cold Mass in the Cold Mass Assembly Area Transport the Cold Mass to CAF-ICB

7. Fermilab CM assembly sequence (part 2) 5.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop7 Install the String assembly with the cold mass into the Vacuum vessel in the Vacuum Vessel Assembly area Install the Cold Mass back to the Cold Mass Assembly Fixture in Cold Mass Assembly Area Align Cavity String to the Cold Mass Support Ship Completed Cryomodule to ILCTA- NML for testing

8. Fermilab ILC cavity: international effort ILC cavity fabricators –Research Instruments (Germany) –Zanon (Italy) –Advanced Energy Systems (US) –Niowave and Roark (US) –PAVAC (Canada/US) –Mitsubishi Heavy Industries (Japan) –Toshiba (Japan) –Hitachi (Japan) ILC cavity processing facilities –DESY –Jefferson Lab –KEK –Fermilab/Argonne joint facility –(Industrial processing facilities: RI, AES, Zanon) Results from past 3 years have been collected in worldwide database, as a means to further track progress and provide input to ILC machine design 8Ginsburg - NGLS Review Feb 5-8, 2013 5.Apr. 20138Ginsburg (FNAL) 2nd PASI Workshop

9. Cavity from vendors who have manufactured a cavity that has surpassed 35MV/m in vertical test: –ACCEL or ZANON or (AES SN>=5) or (MHI SN>=12) Fine-grain cavity Use the first successful (= no system problem) test Standard EP processing: no BCP, no experimental processes (Ignore test limitation) Second pass –if (Eacc(1 st successful test)<35 MV/m) then if (2 nd successful test exists) then –plot 2 nd test gradient else –plot nothing [assume 2 nd test didn’t happen yet] endif –else plot 1 st successful test gradient –endif “Up-to-second-pass” ILC Production Yield Plot - Method 5.Apr. 2013 9 Ginsburg (FNAL) 2nd PASI Workshop

10. Fermilab ILC Cavity Performance Benchmark Ginsburg (FNAL) 2nd PASI Workshop International cavities from established vendors using established processes 2 nd pass yield for >35 MV/m for integrated sample is (57 +- 8)% for 2010-2012 alone is (69 +- 13)% C.M. GInsburg et al., KILC12, Daegu, S. Korea http://ilcagenda.linearcollider.org/contributionDisplay.py?contribId=85&sessionId=36&confId=5414 1 st pass 2 nd pass 5.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop10

11. Fermilab Gradient Summary Good progress worldwide in cavity production, processing, and test AES has been qualified as an ILC cavity vendor during this activity Progress is a partnership between industry and laboratories, results are dependent on both performing well –Scars, pits, stains, dirt and residue introduced at different steps –Early defects are not typically overcome by the standard processing steps The typical learning curve at each company requires a ‘few’ cavities –constant vigilance required afterwards to stay there Yield statistics to the ILC specification show improvement with time –Utility of XFEL test data for ILC will be limited by XFEL requirements, but huge data set Efforts to exceed ILC gradient spec will continue –Field emission prevention at all gradients remains important Laboratory processing and test facilities are coming up to speed, recent throughput at Fermilab for instance is very good 5.Apr. 201311Ginsburg (FNAL) 2nd PASI Workshop

12. Fermilab  Canadian company with new facility in Batavia  1-cells: 6 fine-grain cavities fabricated –Half use “smart-”bells TE1PAV001-3 First weld together half-cells, then add beamtubes –Half use dumb-bells – TE1PAV004-006 First weld each half-cell to a beamtube, then weld together “smart bell” cavities exhibited multipacting ~18-22 MV/m possibly due to unusual shape  9-cells: 10 fine-grain cavities were ordered; order later changed to 650 MHz New Vendor Development: PAVAC TE1PAV001 12Ginsburg (FNAL) 2nd PASI Workshop5.Apr. 2013

13. Fermilab  Six 1-cells tested extensively from 2008 –BCP/VT @Cornell, some had add’l prep/tests –Useful information learned, e.g., defect on die –Primarily being used for commissioning and materials studies now  Six 9-cells received  QC shows fabrication is not yet as stable as other vendors  Performance is moderate  Tumbling R&D New Vendor Development: Niowave-Roark 13Ginsburg (FNAL) 2nd PASI Workshop5.Apr. 2013

14. Fermilab NR flash BCP’d the six 9-cells – insufficient data to comment AES flash BCP’d the latest batch of six 9-cell cavities – all show some pitting but performance is typically good –Does BCP cause the pitting? Process not well controlled, e.g., acid flow too fast Pitting worse on lower surface than upper –Does material cause the pitting? Pits re-emerge after tumbling R&D on sheet corners anticipated RI did bulk EP on half of the latest batch (six of twelve) –Performance more likely to improve after heavier “light” EP So far, no performance advantage, but potential advantage justifies a controlled promotion of industrial processing –AES has a new EP machine –Process was qualified on a 1-cell cavity –AES to bulk EP six cavities this year Vendor Surface Processing 14Ginsburg (FNAL) 2nd PASI Workshop5.Apr. 2013

15. Fermilab Industrial Surface Processing 5.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop15

16. Fermilab TB9AES013: Pits observed in all three images, but generally enhanced by EP. Pits are not restricted to just the equator weld or the heat affected zone. 1) Optical inspection of equator weld before EP 2) Photo before electropolishing. 3) Photo after electropolishing ( ~ 120 microns removed) Cavities Flash BCP’d at Vendor 1 2 3 16Ginsburg (FNAL) 2nd PASI Workshop5.Apr. 2013

17. Fermilab Cavities Bulk-EP at Vendor RI bulk-EP removal amount (um) 133 153 138 130 152 140 *KEK grinding repair * 17Ginsburg (FNAL) 2nd PASI Workshop5.Apr. 2013

18. Fermilab Value Engineering: FNAL Dressed Cavity Cavity Costs 63-71% 11-12% 11-13% 6-13% Dressed Elliptical SRF Cavity Fully Burdened Cost Breakdown *Fermilab Costs Second Pass HPR Reprocess Processing is ~ 13% of the cost of a dressed cavity 18Ginsburg - NGLS Review Feb 5-8, 2013 5.Apr. 201318Ginsburg (FNAL) 2nd PASI Workshop

19. Fermilab Estimated FNAL Cost Breakdown Fully Burdened Cost Breakdown *Fermilab Costs 26%*13% =4% of the cost of a dressed cavity is material removal Processing costs dominated by touch labor 19Ginsburg - NGLS Review Feb 5-8, 2013 Value Engineering: FNAL/ANL Cavity Processing 5.Apr. 201319Ginsburg (FNAL) 2nd PASI Workshop

20. Fermilab Value Engineering: FNAL ILC Cryomodule ILC Type-3 Cryomodule M&S actual cost 43% 26% 15% 20Ginsburg - NGLS Review Feb 5-8, 2013 5.Apr. 201320Ginsburg (FNAL) 2nd PASI Workshop

21. Fermilab FNAL CM Assembly Throughput 21 13 days 14 days 9 days 8 days 14 days 5.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop

22. Fermilab FNAL Cryomodule Assembly CAF infrastructure is fully functional for the 1.3 GHz pulsed cryomodule assembly. We have assembled two 1.3 GHz and one 3.9 GHz cryomodules at CAF. Our experience is still too limited to fully assess each step of the assembly and make optimization. New assembly tooling will be needed to assemble the 325 and 650 MHz cryomodules but the main infrastructure of the CAF looks adequate to assemble these cryomodules. Cavity dressing/qualification and assembly components preparation for cryomodule assembly will probably require some automation in order to increase the throughput for future projects. Cryomodule assembly throughput requirements will dictate hiring and training technicians. Training required for CM assembly is lengthy, especially for cleanroom work. 225.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop

23. Fermilab ILC Industrialization Workshops Two ILC industrialization workshops took place, with substantial industrial and lab participation –PAC10 Kyoto satellite meeting http://ilcagenda.linearcollider.org/conferenceDisplay.py?confId=4530 –SRF2011 Chicago satellite meeting http://ilcagenda.linearcollider.org/conferenceDisplay.py?confId=5182 Discussion topics: niobium material, cavity fabrication, industry regional differences, CM fabrication Webpages provide a useful resource 5.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop23

24. Fermilab 5.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop24

25. Fermilab Summary 5.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop25  ILC has provided a great opportunity for US SRF industrial development  Cavity vendor development  Cavity processing vendor development  Cavity and cryomodule value engineering exercises are ongoing for future projects  Existing industrialization workshops (ILC) provide a resource for understanding cost reduction targets

26. Fermilab Acknowledgements Many thanks to our Fermilab, national, and international collaborators for their hard work and excellent contributions to the cavity and cryomodule development presented here Material for this presentation was provided by T. Arkan, J. Kerby*, A. Rowe (FNAL). *now at Argonne National Laboratory 5.Apr. 2013Ginsburg (FNAL) 2nd PASI Workshop26