1. The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404. Update on D1 M. Sugano, T. Nakamoto, H. Kawamata, S. Enomoto KEK HiLumi LHC WP3 Meeting, Feb. 25, 2015

2. 2 Design modification for 1st 2-m model

3. 2-D cross-section of coil (Ver3.0) Cable: NbTi MB cable with APICAL and PIXEO insulation supplied by CERN Coil configuration: -Single layer coil -44 turns, 4 coil blocks -2D cross-section optimized for HX-hole of  60 mm at R90 (Reported by Sugano at HL-LHC annual meeting in 2014 Nov.) Main body of iron yoke (PF=0.98) Slot region (PF=0.95) Keys(PF=0.96) Stack tubes (PF=1) SUS collar (  r =1) Circular cryostat Coil blocks HX hole (  60, R190) ROXIE Model 3

4. 4 Issues in coil end of 2-m test coil -1 There is difference in height at the boundary between the end spacer and the cable To make the cable stand more upright by elongating the length of coil end The QPH could be damaged Approach 1: Modification of coil end shape (Baseline) Approach 2: Filling the gap with shoe

5. Issues in coil-end of 2-m test coil -2 Gap btw cable and end-spacer Coil size measurement End-saddle was detached This part of the cable did NOT touch the end-saddle -Cable should be fitted more to the end-spacers  Modification of coil-end design -How to fill the gap after curing ? 5

6. Modification of coil-end design Old version (Ver 2) Coil-end found in practice winding (2-m test coil) Modified design (Ver3) Points in modification of coil-end designs -Elongation of end part To make the cable stand more uprightly -Subdivision of the outer most block To make it easier to predict the angle of the last turn -Adjustment of distance between the blocks “1B” and “2” To minimize integral multipole Subdivision 6 This modified coil end will be adopted for the 1st 2-m model 1A1B 2 3A 3B 4A4A 4B

7. Comparison of specifications btw Ver2 and Ver3 Ver2 (Previous version) Ver3 (Modified design) 2-m test coil1st 2-m model Nominal dipole field5.60 T5.59 T Field integral35.2 T m35.0 T m b 3 in SS-0.053 unit-0.059 unit ∫B 3 dl / ∫B 1 dl  10000 8.27 unit2.02 unit Peak field 6.45 T at center 6.71 T at coil end 6.45 T at center 6.59 T at coil end Load line ratio 76% at center 78% at coil end 76% at center 77% at coil end Magnetic length6.27 m Coil mechanical length6.46 m6.60 m 7

8. ROXIE2Catia Thanks to help from Benoit Lepittevin and Susana Izquierdo Bermudez at CERN, we started to use the macro of ROXIE2Catia 8 How to generate the NC data of end spacers for machining from ROXIE data ? In KEK.cnc file from ROXIE (text data including group of points of end spacers) 3D modelNC data At CERN “ROXIE2Catia”: Software to build a 3D Catia model automatically from.cnc file NXCatia

9. 9 Additional tests and practice utilizing 2-m test coil

10. Electrical test of 2-m test coil (Surge test) 10 Surge test up to 1 kV has been done after 2-m test coil fabrication, but we were suggested to do the test up to 5 kV at HL-LHC annual meeting in 2014 Nov. Soundness of electrical insulation was confirmed at least up to 4 kV (which is the maximum applicable voltage in our device)

11. 11 Practice of instrumentation -Routing of the voltage leads -How to fix the lead wires ? Making a rectangular groove on the wedges and fixing the wire with stycast -Practice of soldering the leads

12. Dummy curing with 2-m test coil 12 Three thermo-couples were directly attached to the test coil and their temperatures during curing were compared with temperatures at the forming block and mandrel Hardening of cyanate ester Bonding of polyimide insulation Difference in temperature was less than 5 o C Temperature of the coil is close enough to temperatures measured at forming block and mandrel Mandrel Forming-block Heater Thermo-couples on the coil Coil A B C Longitudinal centerLead end Thermo-couples 150 o C 180 o C > 190 o C

13. Filling gap with cyanate ester 13 Gap between cable and end saddle was filled with cyanate ester impregnated Al 2 O 3 cloth, and then 2-m test coil was cured again -Cyanate ester could be hardened after curing -End saddle was not detached even after coil size measurement This would be one of the ways to repair the coil in case gap was found after curing

14. 14 Collaring and yoking demonstration

15. Collaring demonstration 1 15 The collar press for MQXA with electrical hydraulic pump was reused, but the lock pins could not be inserted because 4-way split collar could not be pressed equally Laser-cut stainless steel collars (4-way split) Collaring mandrel Dummy coil Insulations Pre-assembly with thinner lock pins Lock pin Concept of 4-way split collar was verified in collaring test

16. 16 Collar press was rotated by 45 o and each hydraulic cylinder is connected to manually operated pump to be controlled independently - All of lock pins could be successfully inserted - Size of the collared coil is as designed Collaring demonstration 2 As a next step, we will follow the same procedure with straight section cut out from the test coil (200 mm mock-up)

17. Yoking 17 The yoke will touch taper of the collar to prevent the collared coil from rotating with respect to the yoke (Pre-alignment) Collared coil will be finally aligned by the triangular notch Effectiveness of this alignment feature was verified Yoke Collar Taper Yoke Collar Triangular notch

18. 18 Yoking demonstration 1 Soon after the yoke passed through the taper, the collared coil started to rotate  The taper was too short Inner surface of the laser-cut yoke stack was polished and lubricant was painted to enhance slipping of the collared coil Yoke Collar

19. 19 Yoking demonstration 2 -Collared coil could be aligned with triangular notch and the keys could be also inserted -The gap between the collared coil and the yoke suggests that collared coil was not perfectly aligned even by triangular notch Gap

20. 20 Possible modification of collar and yoke design Extension of the taper of collar Rectangular notch like RHIC dipole -Impact of rectangular notch on field quality will be checked -Modified collar and yoke will be manufactured by laser-cutting and yoking test will be repeated

21. Preparation for Coil Winding 21 CAD/CAM model is being built. It was found that the latest machining center (5 axes) at KEK is not capable to fabricate the end-spacers (Ver. 3) due to the size limitation. The previous machining center (3 + 2 axes) will be used for the model coils. – But, this machine is fully occupied for the SuperKEKB until the end of March. The coil winding will be started in May. Wedges will be delivered by the middle of April. Jigs and tools is also being modified in accordance with the new design (Ver. 3).

22. Procurement: Collar, Yoke 22 Fine-blanking dies for collars and yokes with a “original design” are mostly completed. – Trial blanking to check the dimensions are ongoing. As shown in the assembly demonstration using 200 mm long mock-up, interfaces of collars and yokes need to be modified for the 2-m models. – Audio conference with the manufacturer will be held on this Friday: partial modification on dies or additional work on the collars and yokes. – Delay in schedule is not clear in the meantime.

23. QPH & Spot Heater 23 QPH would not be necessary for the production magnet because peak temperature is estimated to be 300K with 75m  dump resistor by a conservative scenario. – But, it would be nice to test the QPH in the 2-m long models. – No QPH manufacturer in Japan. We need a help from CERN to provide the QPH. Heater pattern could be adjusted to the design for CERN magnets (MQXF, 11 T) for the minimum effort. Spot heaters are now ready. Conceptual drawing for QPH Spot heater on the test coil

24. Preparation for Cold Tests Procurement – New header w/ larger warm bore – New 15 kA CLs to be delivered in March 2015 – Upgrade of PC and bus lines. (7.5 kA >> 15 kA). New 15kA-DCCT procured by KEK is being calibrated at CERN. New dump resistor of 75 m  with grounding at the middle. – New DAQ systems Completion inspection by the local government in May 2015. Commissioning at 1.9K, 15kA without magnet in June 2015. Cold test of the 1st model in Sep. or Oct. 2015. – Only possible time slot in JFY 2015. Because the operators are reserved for the commissioning of SuperKEKB. The test schedule will be reconsidered in July based on the latest commissioning schedule of SuperKEKB. 24 New 75 m  dump resistor New 15kA-DCCT (calibrated by CERN) New 15kA Current Leads

25. SC Cable Supply & Schedule 25 Delivery DateObjectiveRequirementRemark Feb. 2013 10 stack meas. (a piece length > 0.3 m) ~50 m w/ MB type insulation Both MB inner and outer cables w/ MB type insulation Jan. 2014 May 2014 1 practice coil * + 2 real coils for the 1 st 2-m long model + 1 spare coil 220 m ** x 4LHC MB outer cables w/ MB type Apical insulation April. 2015 May 2015 2 coils for the 2nd 2-m long model + 2 spares 220 m x 4LHC MB outer cables w/ MB type Apical insulation JFY2016 (prospect) 6 or 7 full-scale magnets + 4 practice/spare coils 600-640 m x 18LHC MB outer cables w/ MB type Apical insulation Done!! NbTi LHC MB outer cable supplied by CERN for the new D1. Done!! SC cables for the 1st model are in hand. Request for the 2nd model sent to CERN Feb. 4, 2015. - Need follow-up.

26. 26 Schedule in JFY2016 (April 2015 to March 2016) *Work related to the 1st model fabrication Feb. 2015A 200 mm mockup for assembly demonstration. (~April) >> Test with different interfaces, conditions. Laser cutting process. May 2015Coil winding (~June) June 2015A 200 mm mechanical short model by fine-blanking (schedule unclear) Commissioning of the test station July 2015Collaring and Yoking Aug. 2015Shell, splice work Sep. 2015Cold test of the 1st model (or October): 1 st cycle Oct. 2015Start of fabrication of the 2nd model (if no design change…) Jan. 2016Cold test of the 1st model: 2 nd cycle >> Possibly rejected by the schedule of SuperKEKB, budget for testing. March 2016Shipping the 1st model to CERN.

27. 27

28. 2m-long Model Magnet - Overview 28 Shell: SUS304L Horizontal split iron yoke: low-carbon steel (EFE by JFE steel) Collaring keys  60 mm HX hole Notches and  34 mm holes for iron saturation effects Same outer-interface for J-PARC SCFM jigs 4 split stainless steel spacer collars: NSSC130S NbTi SC cable (LHC MB outer) + Apical insulation Radiation resistant GFRP (S2 glass + BT resin) wedges Brass shoes Single-layer coil, 4-split spacer collars, collared yoke by keying HeII cooling channel