Cavity and Cryomodule R

1
Cavity and Cryomodule RD

• Shekhar Mishra
• Fermilab

2
Outline

• Technical Goals
• FY06-07
• Cavity Fabrication (1.3 and 3.9 GHz)
• Cavity Processing
• Jlab
• Cornell
• Cryomodule
• Fabrication Plan
• T4CM Design
• Industrial Development
• Plans for FY08-09
• International Collaboration
• Summary

3
Technical Goals

• Demonstrate the basic ILC Main Linac technology
• Develop cavity processing parameters for a
  reproducible cavity gradient of 35 MV/m improve
  the yield of 9-cell cavities for gradient of 35
  MV/m in vertical tests (S0.1).
• Carry out parallel/coupled RD on cavity
  material, fabrication, and processing to identify
  paths to success (S0.2).
• Assemble and test several cryomodules with
  average gradient gt 31.5 MV/m (S1).
• Build and test one or more ILC rf units at ILC
  beam parameters, high gradient, and full pulse
  rep rate (S2.1).
• Carry out Key Alternate Design RD item
• GDE wants a forward looking approach
• Improve ILC performance, reduce cost
• Install Sufficient Infrastructure to support
  these activities

4
US Cavity

• 1/3 of the Global Need With focus on getting US
  Industry involved
• FY05
• 4 Cavities from ACCEL
• FY06
• 4 Cavities from AES
• 4 Jlab (2 Fine, 2 Large)
• 9 Cavities from ACCEL
• 6 Cavities from AES
• FY07
• 16 Cavities
• FY08-09
• 24 60 Cavities (Proposed)

5
US SRF Infrastructure Strength

• Cavity Processing and Vertical Testing RD
  Facility
• Jlab (30 FY07, 40 FY08, 50 FY09) cycles/yr
• ANL/FNAL ( 10-20 FY07, 30 FY08, 40 FY09)
  cycles/yr
• Cornell 12 cycles/yr
• VTS _at_FNAL 45 cycles/yr (08)
• Horizontal Test Stand
• FNAL 24 cavities/yr
• Cavity Dressing and Cryomodule Assembly
• FNAL 4/yr (FY07)
• Limited cavity fabrication capability in US
  industry

6
Cavity Fabrication 1.3 GHz

• Four DESY TTF style cavities with asymmetric beam
  tubes (Type III) were purchased from ACCEL in
  FY05.
• Two of these cavities have undergone EP
  processing and vertical testing at TJNL.
• The remaining two cavities are being processed
  and tested at Cornell
• Four additional Type III cavities ordered from
  AES in FY06 were recently completed.
• Three of these were shipped to TJNL processing
  and vertical testing is in progress.
• The fourth cavity was shipped to FNAL for
  mechanical and RF measurements. From there it
  will go to TJNL for processing and vertical
  testing.
• All the cavities listed above were fabricated
  from fine grain niobium.

7
AES - 001
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Cavity Fabrication 1.3 GHz

• In a collaborative effort with FNAL, Jlab has
  developed the tooling and infrastructure to
  fabricate 1.3 GHz cavities.
• Jlab has completed a prototype cavity (Type III)
  to fine tune the tooling,
• Jlab has fabricated two Type IV (symmetric beam
  tubes) cavities using large grain niobium.
• Both large grain cavities are scheduled for
  mechanical measurements, BCP processing and
  vertical testing in the near future.
• Jlab is also completing two Type III cavities
  using fine grain niobium.

9
Cavity Fabrication Industry Development

• Purchase orders were issued for fourteen
  additional Type IV cavities, six from AES and
  eight from ACCEL.
• ACCEL has acquired all necessary material and has
  shipped the half-cell blanks to FNAL for eddy
  current scanning.
• Material for AES is currently in Inspection at
  FNAL to verify conformance with the FNAL niobium
  specification.
• Delivery date for these cavities is projected to
  be during the fourth quarter of FY2007.
• First step toward developing additional US Cavity
  vendors for cavity fabrication,
• Phase I of multi-phase program is funded with
  Roark Engineering. Roark is building three 3.9
  GHz single-cell cavities to develop expertise in
  niobium machining, forming and EB welding.
  Tooling for forming the half-cells was provided
  by FNAL.
• Fermilab is working with Roark and Niowave in
  developing a collaborative venture

10
Cavity Fabrication Plan

• Goals and plans for the remainder of FY2007 and
  beyond
• Solicit bids from industry for six or twelve Type
  IV cavities (plus options for four additional
  cavities).
• FNAL will evaluate all positive responses based
  on technical merit, proposed schedule and cost.
• Roark/Niowave collaboration with the goal of
  fabricating a single-cell 1.3 GHz cavity,
  followed by one or two nine-cell Type IV
  cavities.
• FNAL and Jlab will continue collaborative efforts
  to develop additional US vendors for cavity
  fabrication.
• In FY2008/09 the plan is to issue purchase
  requisitions for 24/60 Type IV cavities.

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Fermilab 3.9 GHz Status

• Status
• 4 cavities fabricated
• 4 built at Jlab
• Trimmed HOM F-part tip
• (peak surface field reduced by 2.5)
• 2 cold tests both gt20MV/m
• No HOM heating during quenches
• Meets criteria
• Outlook
• Up to 6 more cavities to build and test
• Commission Horizontal test stand in a few weeks
• Cavity 3 first to be welded into a helium vessel
  and horizontal tested
• Goal is to ship completed Cryomodule in March
  2008

12
U.S. Cavity Processing Test
Cavity Fabrication By Industry
Surface Processing _at_ Cornell
Surface Processing _at_ Jlab
Surface Processing _at_ ANL/FNAL
Vertical Testing _at_ Jlab
Vertical Testing _at_ Cornell
Vertical Testing _at_ FNAL
Exists
Cavity Dressing Horizontal Testing _at_ Fermilab
Developing
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Jlab ILC Electro-polish and Vertical Test

• Production Like Process Established
• 12 Vertical RF Test completed
• 5 Bulk chemistries and 11 final chemistries
  completed
• 2 Cavities qualified for S0 program
• Rate of 50 processes/year achieved with 3 FTEs
• Current Issues
• Production rate is limited by tooling sets and
  facility availability
• Cavity Performance
• Quench limits reached in all but 1 RF test
• Field emission no problem below 30MV/m
• A7 Reached 42MV/m on 2nd Qualify Test
• AES built cavities testing started 18 MV/m so
  far
• 1 - Single cell baseline test completed
• Easily reach the 10 planned tests for FY07

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Results of Accel Cavity A7
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Material Removal Data A7 Equators
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Results of Accel Cavity A6
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Material Removal Data A6 Equators
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Results of AES Cavity AES1

• Investigating the limitation Could be several
  things
• Weld joint
• Preparation defects
• Machine cut at equator
• Multipacting
• Material (Initial Problem)
• We are working with AES to understand and solve
  this problem.

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Results of AES Cavity AES1
Analysis of Stored Energy Sqrt(PQ) for AES1 Test
2
FPC
Mode
Cell1 Cell2 Cell3 Cell4
Cell5 Cell6 Cell7 Cell8
Cell9
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Material Removal Data AES1 Equators
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Radiation Summary
22
Clean Room Particles Activity
T. Rothgeb JLab
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Vertical EP ACCEL- 8 Test Results

• BCP 110 ?m ( 50 ?m on parts at ACCEL) HPR
• No Heat treatment at 800 Deg C
• Eacc 26 MV/m (Limit high field Q-slope)
• Vertical EP, 25 microns, bake 110 C, 48 hours
• Eacc 30 MV/m
• No field emission
• Limit quench
• Vertical EP 70 microns
• Sent to Jlab for H out gassing

EP25 um
BCP 160 um
BCP100 um
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Vertical EP - ACCEL-5

• Vertical EP 120 micron
• 600 C, 12 hour bake at Jlab to remove H
• Flash BCP (lt 10 microns) HPR test
• Eacc 17 MV/m (max)
• No field emission
• Need more material removal after furnace bake
• Vertical EP, 25 microns
• Eacc 24 MV/m, Flat Q vs E, Quench
• Remove another 105 microns, sent to Fermilab for
  H outgassing

Vertical EP
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Cryomodule Fabrication

• Fermilab plans to assemble 1st cryomodule using a
  kit from DESY in CY07.
• 2 cavities of this kit is here at Fermilab
• Another 2 are ready for shipment, Rest is
  awaiting horizontal test at DESY
• The cold mass is getting ready to be shipped.
• Fermilab plans to assemble 2nd cryomodule using
• Cavity purchased and processed in US ( 10
  cavities )
• The cold mass has been ordered through INFN from
  Zenon
• The tuner and associated parts have been ordered
  through INFN
• Couplers have been bought from CPI and will be
  processed at SLAC
• We plan to assemble this cryomodule in mid FY08.
• Cryomodule 3 and 4 (Type-IV)
• Proposed to be ordered by FNAL in FY08

26
T4CM Design

• Fermilab is leading an international effort in
  design of the ILC T4CM, with INFN (Milan and
  Pisa), KEK and CREN.
• A detailed plan of who is working on what and
  co-ordination between groups exits.
• Two cryomodules will be designed
• 9 cavities w/o magnet
• 8 cavities w/ magnet package.
• The deadline for completing a drawing package for
  the first cryomodule has been set by Fermilab to
  be October 1, 2007.

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T4CM Design. The Master Spreadsheet
Hyperlinked to a detailed PDF drawing
Values which can be modified
Shrinkage Calculations
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T4CM Design. WITH 9 CAVITIES
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Development of Industry
The technology for cavity fabrication
processing, cavity dressing and cryomodule
fabrication will be transferred to
Industry. Cryogenic testing of cavities and
cryomodules along with beam tests will remain
the responsibility of US laboratories.
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Industrial Development

• We plan to work with US industry technology
  transfer to Dressed and tested Cavity Fabrication
• The qualified US vendor will fabricate Cavity,
  Coupler, He Vessel, Tuner in Industry
• The cavity vendor could work with a processing
  industry and Fermilab to process and vertical
  test the cavity
• The coupler and He vessel industry could work
  with Fermilab in dressing and horizontal testing
  of cavities.

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RDR US Cost Estimate

• U.S. effort to develop a cost estimate for ILC
  cryomodules was split into two parts
• Internal Estimate
• Using team from FNAL, JLab and SLAC
• Developed a cost model using engineering
  estimates, vendor quotes, scaling from actual
  purchases, etc. as basis
• Costed all elements of cryomodule construction
• MS Excel based (easy to modify to look at
  scenarios)
• Used as U.S. input for RDR cost estimate
• Industrial Cost Study (first part cryomodule
  only)
• Industrial team led by AES, Meyer Tool and CPI
• Got a very late start (inability to get PO in
  place) but made up a lot of time and produced a
  final report in early 2007
• Very systematic with many details and vendor
  quotes as back up
• Presentation at PAC 2007 (June - Albuquerque)

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Main Assumptions

• A government-owned facility (The Factory) will
  provide the equipment and space for
  superconducting cavity fabrication and
  processing, and integration and checkout of the
  cryomodules
• Located at or nearby Fermilab.
• The cost of the setup of The Factory is not part
  of this study
• Industry will conduct the work at The Factory, so
  they will also operate it (overhead GA costs
  included)
• RF Equipment will be procured through the local
  ILC program infrastructure not through The
  Factory

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Resulting Top-Level Costs (Normalized)
Quantity of RF Units 1 250 750 Total
Quantity Cost 2.35 250 694 Per RF Unit
Cost 2.35 1.00 0.92 CM w/Magnet (1 per RF
Unit) 0.51 0.23 0.21 CM wo/Magnet (2 per RF
Unit) 10.33 0.20 0.20 Per RF Power System
1.17 0.36 0.32
(1) The fidelity of the cost estimate is /-
24 (2) The cost of one RF Unit in this study is
not representative of what the cost of an initial
prototype would cost today because the single
unit cost presented herein is based upon
production methodology that is not yet in place.
Nominal Case
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Industrial Studies

• The US industries have suggested several cost
  reduction concepts in the US cost study.
• We are in process of developing cost reduction
  and value engineering proposal with LCFOA
• Cavity End Group Design
• Cryomodule Design
• Cryogenic
• We will also pursue the idea of getting industry
  involved in our 2nd Cryomodule fabrication

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FY08-09 Plans

• WBS 2.9
• Main Linac RDR/EDR Cavity and Cryomodule
• WBS 3.9
• Cavity Fabrication
• Cavity QC and Tuning
• Cavity Processing and Vertical Testing
• Single Cell Processing RD
• ACD Shape and Material (LL, Reentrant, Large
  Grain, Single Crystal)
• Cavity Failure and Improvement of Manufacturing
  Yield
• RD on Cavity Processing
• ILC Cryomodule
• SCRF Material Research
• WBS 7.9
• Industrial development
• Cavity and Cryomodule Processing and Testing
  Infrastructures

36
Cavity Processing and Testing

• The present US cavity RD is using
• Distributed Cavity Processing and testing
  infrastructure
• This is an ideal way to get started with very
  limited resources to make significant progress
  towards the ILC RD goals.
• The production of high-performance SRF cavities
  will require state-of-the-art surface
  preparation.
• We are proposing build additional facility at
  Fermilab, We already have
• Existing infrastructure and significant
  engineering resources
• Low and High Power Cavity Test Facilities
• Cryomodule Assembly Facility
• Cryomodule Test Facility With and Without Beam
• An integrated facility will be needed
• For significant improvement of the current
  preparation
• Steps towards an industrial production-like level
  
• A large enough throughput (100 cavities/yr)

37
MSU LANL Work Package

• MSU RD Program
• Cavity Autopsy
• Single Cell Cavity (RD)
• Advanced Cavity and Material Science studies
  (RD)
• MSU SRF Infrastructure
• Upgrade ultra-pure water and high pressure rinse
• Nine-cell structure vertical test dewar
• LANL RD Program
• Cavity Autopsy
• LANL SRF Infrastructure
• Re establish cavity testing at LANL
• 1.3 GHz Power Amplifier
• Thermometry provided by Fermilab

38
Cornell Jlab Work Package

• Cornell ILC RD
• Processing and Vertical Testing of 9 Cell Cavity
• Process 12 cy/yr in FY08
• Single Cell RD to improve the Processing
• High Pulse Power RD
• ACD Reentrant Cavity Fabrication and Processing
• Jlab ILC RD
• Processing and Vertical Testing of 9 Cell Cavity
  
• Process 30 cy/yr in FY08
• Single Cell RD to improve the Processing
• Field Emission studies for tracking the
  contamination
• ACD LL Shape Cavities, Large Grain and Single
  Crystal

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ANL Work Package

• Electropolish S0.2 ILC cavities
• 30-50 Cy/yr
• Installation of a PLC-based control system for EP
  
• Install new HPR system
• Single Cell Cavity RD
• ANL and Fermilab will work together in cavity
  processing and testing.

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Fermilab Work Package 08

• Order 24 cavities
• Heat treat, tune, HPR and Vertical test 30-50
  cycles/ EP at Argonne
• Horizontal test 8 good cavities
• Work with LANL and MSU to supply thermometry
  diagnostics for failed cavities
• Single cell RD and Materials RD collaboration
• Continue Testing First cryomodule (type III)
  assembled in 07 from DESY supplied cavities
• Assemble and Test cryomodule 2 (Type III)
• Order parts for 2 Cryomodule Gen IV

41
Fermilab Work Package 08

• Continue Next Generation CM design,
  manufacturability, transportability, cost
  reduction
• Cavity Tuning Machine
• Involve industry in fabrication of Dress Cavities
  activities
• Start Next Generation and Pre-Production cavity
  processing
• Vertical Test Stand to increase Capacity
• RF unit infrastructure

42
International Collaboration

• American Regional Team is collaborating on ILC
  Cavity and Cryomodule RD.
• We are participating in the S0, S1 and S2 RD
  programs
• US purchased/produced cavities will go to KEK and
  DESY for Tight Loop S0 processing
• KEK and DESY cavities will come to US for
  processing.
• We are coordinating the ILC Cryomodule Design
  effort
• We collaborate with INFN in development and
  testing of Tuner
• We are developing new collaboration
• India (RRCAT, BARC, IUAC, UD) joined TTC
• Detailed MOU is in preparation that could lead to
  an RF unit fabrication
• India is fabricating Cavity fabrication tooling
• Two scientists from India will spend time at
  Fermilab and coordinate work at Indian
  laboratories.
• TRIUMF
• Cavity fabrication
• Tuner

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Summary

• We have made considerable progress in building US
  infrastructure for cavity fabrication, processing
  and testing.
• We are ready to play a significant role in cavity
  and cryomodule RD
• Cavity Processing (gt 30Mv/m)
• Cryomodule design and fabrication
• The initial plan for FY08-09 is in place
• This uses the developed strength of the US
  laboratories in cavity processing
• We are developing significant infrastructure at
  Fermilab
• We will work with US industry
• International Collaboration