1. Manufacturing process, validation and factory test
ESS RFQ CDR Bruno POTTIN

2. Table of contents
1: Copper + HIP 2: Ancillaries 3: Section manufacturing 4: Brazing process 5: Couplers 6: Tuners 7: Acceptance factory test
Bruno POTTIN

3. SECTION MANUFACTURING
One RFQ section manufacturing’s steps process
Bruno POTTIN

4. SECTION MANUFACTURING
1 Copper + HIP
One RFQ section manufacturing’s steps process
3 Section manufacturing 4
Brazing process
2 Ancillaries
Bruno POTTIN

5. Copper and HIP
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

6. Copper and HIP One RFQ section manufacturing’s steps process
Bruno POTTIN

7. Chosen material: Cu-OFE
Cu-OFE is chosen for our application (NF EN 13604)
Already used for other RFQ (IPHI, LINAC4, Spiral2)
Cu-OFE can be machined and brazed « easily »
Addition of a prevention step: HIP (High Isostatic Pressing)
To avoid porosity / casting defects
Example of an porosity in IPHI
copper on a brazing plan
Bruno POTTIN

8. Copper providing process
Copper OFE
Chemical composition analysis
3D forging
5 mm peeling
Annealing
Grain size
Hardness
Ultrasonic testing
Delivery in course
HIP treatment process was validated with mock-up
HIP treatment after copper delivery and before starting machining :
920°C bars – 2h
Argon gas
HIP
High Isostatic Pressing
Order in progress
Call for tender
Manufacturing
Bruno POTTIN

9. HIP treatment mock-up Ø 1 Ø 2 Ø 3 Assembly by brazing HIP treatment
3 holes : 1,2 and 3 mm diameter
Bruno POTTIN

10. HIP treatment mock-up Before After HIP, we have : Holes disappeared
Metallographic study :
Grain size increase
Low hardness
After
Bruno POTTIN

11. HIP EQUIPMENT Major vane Minor vane 6 sections (5 + 1 spare)
HIP treatment in one step
for all the sections copper
 Same copper quality for manufacturing
Major vane
Minor vane
3 possible levels in the oven
Capacity :
12 major vanes
18 minor vanes
Needed :
12 minor vanes
6 sections (5 + 1 spare)
Bruno POTTIN

12. ancillaries
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

13. SECTION MANUFACTURING
One RFQ section manufacturing’s steps process
Bruno POTTIN

14. MAIN TECHNOLOGICAL CHOICES
IPHI
ESS
Ancillaries :
Tuner ports : stainless steel with copper coating inside and nickel coating outside
Section flanges : stainless steel with nickel coating
Pumping grids machined directly on the vane
Technological problem to braze the stainless steel on the copper module
Brazing copper to copper and stainless steel to copper in 1 step
To avoid machining of the pumping grids on the vanes  decrease the machining difficulty
Ancillaries :
tuner ports
pick up ports
section flanges
pumping grids
a first correction of the error on the machining of the vanes before brazing by adjusting the penetration of the pumping port
2 brazing steps :
Stainless steel to copper for ancillaries
Copper to copper for module + ancillaries
Using copper
No copper coating inside
No nickel coating outside
No coating  simpler
Final machining adjustment for brazing on copper
IPHI
Bruno POTTIN
IPHI

15. ANCILLARIES MANUFACTURING
Ancillaries manufacturing’s steps process
Tridim
measurement
Leak test
Bruno POTTIN

16. ANCILLARIES PROCUREMENT : TEST CAVITY
Mock-up validation of brazing ancillaries on copper cavity as RFQ
Brazing section flange
Brazing tuner port
Brazing coupler port
Brazing pumping grid
Brazing pick up port
Validation with leak test and
tridim measurements
The test cavity is useful for the couplers conditioning
Bruno POTTIN

17. sECTION machining
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

18. MAIN TECHNOLOGICAL CHOICES
IPHI’s project : 4 copper parts per section  chosen for ESS
Machining
Assembly
Brazing copper parts and ancillaries in vertical position in 1 step
Bruno POTTIN

19. SECTION MANUFACTURING
One RFQ section manufacturing’s steps process
Bruno POTTIN

20. SECTION MANUFACTURING
Manufacturer and process validation
2 major technical phases to be tested in parallel
Step1
Qualification of deep drilling and machining technic
Validation of process and manufacturer capacity with his equipment
Ultrasound test and tridim measurement
Machining mock-up
Deep drilling mock-up
Step 2
Qualification of vertical brazing process
Validation of manufacturer brazing process
Tridim measurement and leak test
Brazing mock-up
IPHI
 Schedule and process adaptation to reach the ESS schedule
Bruno POTTIN

21. SECTION MANUFACTURING
To start the third step, the steps 1 and 2 must be done
Step 3
Qualification of a total section manufacturing : Section 1
Leak test, tridim and RF measurement
To start the series production, the step 3 must be validated
Series production
Sections manufacturing : process adaptation with industrial
Following process to optimize the time
Leak test, tridim and RF measurement
Development plan and validation test according to the qualification phase
Bruno POTTIN

22. SECTION MANUFACTURING validation
One RFQ section manufacturing’s steps process
Specific validation operations will be done
by CEA or with CEA presence
Tridim and RF measurement
Tridim
measurement
Bruno POTTIN

23. SECTION MANUFACTURING
Brazing
Machining
RF validation
Vacuum leak test validation
TriDim
Bruno POTTIN

24. Brazing process
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

25. SECTION MANUFACTURING
One RFQ section manufacturing’s steps process
2 different brazing processes
Bruno POTTIN

26. 2 Brazing processes Two different brazing processes used
Ancillaries manufacturing
Small pieces (small oven)
Stainless steel-copper brazing without coating
R&D step to industrialize the manufacturing
Many components
Sections manufacturing
Large pieces (big oven)
Copper-copper brazing
Vertical brazing according to big geometrical movement due to thermal expansion phenomena
The process (not the same brazing) and the equipment (oven size) are different, not the same resources  2 procurements to reach the ESS schedule
Bruno POTTIN

27. SECTION MANUFACTURING
One RFQ section manufacturing’s steps process
Ancillaries adapted for brazing
Tridim measurement to check the section
RF measurement
Brazing
Leak test
Tridim measurement
Bruno POTTIN

28. Couplers
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

29. MAIN TECHNOLOGICAL CHOICES
RF loops (coupler : window + loop)
Same technology as SPIRAL2 (just adaptation)
Possible use of simple coaxial disc RF window smaller and lighter than waveguide window (easier installation)
RF losses smaller than with iris+ridge
(power budget)
Faster adjustment and adjustment flexibility
(RF tuning success)
SPIRAL2
Bruno POTTIN

30. Coupler manufacturing
Qualification PHASE
Step 1 : RF window
Machining and assembly copper-ceramic process
TiN coating
Leak test
RF test before and after TiN coating
Step 2 : double cooling circuit
Machining and assembly process
Tridim measurement
Manufacturing of 3 couplers
Bruno POTTIN

31. Coupler test validation
Conditioning of the 3 couplers with the test cavity and the pulsed klystron in the dedicated bunker.
Coupler will be conditioned until 1MW peak power in travelling wave
Bruno POTTIN

32. tuners
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

33. MAIN TECHNOLOGICAL CHOICES
IPHI
ESS
IPHI
Adjustable tuners
Same geometry during adjustment and operation (same perturbation)
Definitive position just after adjustment
No delay of machining between adjustment and final position
Adjustment possible in operation or after a transport
Adjustement tuners
To do RF tuning
Final tuners for operation
the same dimension
Adapted chock
The correct thickness for each position along the RFQ
Machining delay between adjustment and operation
Impossibility to change the tuners penetration
Bruno POTTIN

34. Tuner manufacturing One prototype with 2 steps Step 1
Bellows qualification after a thermal treatment according to the brazing process with a multi traction test
Validation of the welding
Step 2
Prototype manufacturing
Technological choices validation
Schedule adaptation for series production
Qualification of the mechanical comportment under pressure with the test cavity
Bruno POTTIN

35. factory Acceptance test
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

36. Manufacturing tracking
We will follow each step of manufacturing with presence, measurement, report…
Processes and methods used for manufacturing (deep drilling, machining and brazing)
Operating conditions
Tools for handling and manufacturing
Stabilization for machining (T°, power supply, vibration, calibration, maintenance, oil type …)
Thermal treatment and brazing : oven characteristics and temperature curve
Cleaning process
Storage for the delivery but also during machining
Technical specifications to sub-contractors …
Bruno POTTIN

37. Leak test Vacuum leak test validation According to the ESS handbook
Contract approach:
We specify this requirement in specifications :
During the vacuum test, every leak over mbar.l/s must be repared
Technologic approach:
Study of the leak’s impact (Vacuum, RF…)
ESS-CEA analysis
Repair or not?
Repair consequences : risks, cost and delay
It’s a choice between a slightly degraded component or to repair with risks

38. Other ACCEPTANCE tests
Tridim measurement
Tuning RF measurement
Dimension validation
Displacement qualification
Cavity RF characteristics validation

39. Thank YOU
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

40. THE ESS RFQ MECHANICAL DESIGN
5 x Sections (L= 0.92m) for a total length = 4.58m
2 x Vacuum ports per quadrant and per section except on S3 (hosting the 2 RF couplers)  32
3 x 80mm-diameter pistons per quadrant and per section acting as tuners  60
Pick-up ports 28
8 x 10mm-diameter cooling channels per section (variable length)
RFQ in CuC2 and Flanges in stainless steel
Global Schematic view of
ESS RFQ S1 S5 S2 S3 S4
Transversal view of the RFQ across the tuners
40mm
Cooling channels
View of the end section of the RFQ with the tuning rod for a quadrant
Bruno POTTIN