1. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 1 Vacuum System Undulator Vacuum System Dean R. Walters Soon-Hong Lee, James Bailey, James Morgan, Dana Capatina, Scott Doran, ANL

2. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 2 Beam Finder Wire Undulator Vacuum Chamber Prototypes Production Vacuum System String Test Results Vacuum System Undulator Vacuum System

3. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 3 BFW Production Plan Chamber WeldmentCatalog Items Machined PartsHardware Fixtures Assemble, Weldment/Chamber/Card Leak check and bake out Wire Card Procured Components Work performed at ANL Install Machined Parts/Catalog Items/ Hardware on the Assembly Perform Nominal Alignment Procedure and Operational Tests Package and ship to SLAC

4. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 4 BFW Status of Production Weldment, Machined Parts, Chamber, Catalog Items and all Hardware---- Design and Procurement Documents are complete and are in the procurement process Wire Card is currently under final design. Fixture designs are 90% complete. Alignment and Assembly Procedures are 50% complete.

5. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 5 BFW Production Schedule What is the current Schedule

6. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 6 Prototype Vacuum Chambers Compound screws (Brass Screws & SST ) Vacuum Chamber NW 50 Flange -Clamp Type (316L SST) Top & Bottom Strips (316LN) Chamber Strong-back (20Cb-3) End Cap (20Cb-3) Prototype A Top & Bottom Strips (20Cb-3) Chamber Strong-back (316 SST) End Cap (20Cb-3) Prototype B

7. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 7 Status of Prototype Efforts 42 inch Prototype Completed fabrication Constructed Laser Welding tooling for 42” prototype Leaks repaired with Ag braze First coating Chamber cut up for visual examination Proto B (12 ft proto) Completed all Fabrication’s steps Constructed Laser Welding tooling for 12 ft prototypes Repaired leaks with Ag brazing and Sn-Ag-Cu soldering Completed both Bakes & was coated Unit completed vacuum performance measurement Installed into SUT for straightness measurement Chamber used in String Test Proto A (12 ft proto) Completed all fabrications steps Repaired leaks by Laser Welding Completed both Bakes and was coated Unit completed vacuum performance measurement Chamber used in String Test Chamber has been machined into parts for further examination Coating fixture in place and in use. Pivoting fixture installed All safety inspections complete End stations complete

8. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 8 Production Chamber Permeability (full length Prototype A) As-received Alloy 20 1.009 ~ 1.010 (0.75” thick) After fabrication, permeability  1.013 [spec: 1.02]

9. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 9 Laser Seam Welding - 12 Foot Prototype Fixturing for Strong Back Weld Transferring Fixturing from Strong Back Weld Configuration to End Cap Weld Fixturing for End Cap Weld

10. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 10 Prototype A Laser Welding Drawing shows the location of the leaks The majority of the leaks occur at the weld overlaps The chamber was welded in three sections The chamber was sent back to the vendor of weld repair The chamber was baked after leak repair and none have re-opened

11. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 11 Final Machining Method End Cap Strong Back Side Wall Vacuum Chamber Xsection 1” wide cut by 2-0.030” and 4-0.010” deep 0.020” final wall thickness 1” wide cut by 1-0.100” deep

12. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 12 12 foot Coating Set-up

13. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 13 12 Foot Test – 2/2/2007 Sample Location Sample Location

14. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 14 Coating Results Test were performed by inserting silicon samples into 13 mm ID SST spool. Each test had four samples down the length. In most cases the samples were measured in more than one location Uniformity down the length In three different tests over the 12 foot length Test #1: Average thickness of 98 nm with uniformity of 10% Test #2: Average thickness of 325 nm with uniformity of 4.3% Test #3: Average thickness of 210 nm with uniformity of 12% Results of surface finish Test #1 surface increased roughness by 1 nm Test #2 surface roughness was unchanged by the coating Test #3 surface increased roughness by 2 nm Plans for further measurements

15. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 15 Coating of Proto A Coating of Proto B Performed on 9 Feb. 2007 Repeated on 13 Feb. 2007 Performed on 16 Feb. 2007

16. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 16 Baking the Prototypes Baking of Prototypes A and B Prototype A Prototype B Proto B 1st bake (before coating) at 200 deg C 2 nd bake (after coating) at 150 deg C Proto A 1 st bake (before coating) at 150 deg C 2 nd bake (after coating) at 150 deg C Proto B Base Pressure : 5.9x10 -9 / 1.1x10 -9 Outgassing Rate : avg. of 6x10 -13 Torr-Lit/sec/cm 2 Proto A Base Pressure : 2.2x10 -9 / 2.5x10 -9 Outgassing Rate : avg. of 3x10 -13 Torr-Lit/sec/cm 2 Measurements of Vacuum Performance (Outgassing Rate Spec: 2x10 -12 Torr-Lit/sec/cm 2 )

17. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 17 Vertical Adjustment Screws (14) Chamber Alignment/Survey Results SUT Mockup Chamber Prototype B Chamber Results showed the vertical centerline of vacuum chamber can be within tolerance of ± 200 µm

18. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 18 X-Adjustor Z-Adjustor Support Assembly Production Vacuum Chamber Ass’y Vacuum Chamber Assembly

19. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 19 Fabrication Processes

20. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 20 Preparations for Production Advanced Procurement Plan written and in the process of being signed. Support Assembly SOW completed Purchase requisition in system Chamber Material Alloy 20 for first 4 units in house Alloy 20 for next 8 units have a requisiton placed in the ANL purchasing Purchase requisition for next 25 in system Side Wall Vendor making first article Draft SOW is complete Strongback SOW is complete and being signed Requisition is in the ANL system End Cap SOW is complete and being signed Requisition is in the ANL system All drawings for the chamber and the support have been completed and released. Minor updates have been incorporated. (4) Full sheets of polished 316LN have been bought, samples have had the surface finish measured and accepted for use. Strips have been made from this material and used in Prototype A. The (2) sheets are sufficient for the entire production run. A test run is under way to water jet cut strips and to machine the edges, if this is satisfactory then this vendor will produce the rest of the parts. Material for the first (4) strongbacks have been bought and are ready to be shipped to machining vendors. Samples of material have already been submitted for permeability measurement and have been accepted. Material for the first (8) end caps have been bought and are ready to be shipped to machining vendor. Tooling has been made, and used, for: machining the strongback, laser welding, and final machining.

21. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 21 Chamber Schedule

22. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 22 String Test Results

23. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 23 Concerns & Open Issues Have developed Laser Welding and built tooling with vendor in Iowa. Need qualified strongback machining vendors Will need 2 for production Need to locate qualified Final Machining vendor All Final Machining of prototypes were performed by ANL Central Shops. Continue coating development now that contact is reestablished with thin film consultant. Cost of Nickel is raising, pricing of Alloy 20 is subject to increase. Attempt of offset that by placing order now for future delivery Permeability of Alloy 20 is of concern, since the material used in Proto A is measurably lower in relative permeability than first antisapated further measurements will be performed. Proto A has been cut up and a section will be used for measuring permeability in an ANL undulator. Since performing a vacuum pumpdown string test, Proto A has been cut apart to inspect the internal surfaces.

24. Apr. 16, 2007 Undulator Breakout Dean R. Walters drw@aps.anl.gov 24 Conclusions Two full sized prototypes have been built. All planned fabrication steps have been performed. Seam Welds were performed by Laser Welding. Even though leaks were found, they have been repaired. The vendor is organizing further work to address them. Construction of the 12 foot fixture and initial development of the AC Diode Sputtering process has lead to Aluminum coatings applied to both prototypes. The chambers have been baked and their measured outgassing rate is lower than the specification Many preparations for production are in-process or in place.