ILCSRF R

1

• ILC/SRF RD

Robert Kephart
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Outline

• Fermilab ILC Goals
• Fermilabs role in the GDE the ILC machine
  design
• Main Linac design
• Accelerator physics
• Main Linac components (Cryomodule, RF components)
• ILC/SRF RD and Infrastructure
• Cavity fabrication and processing
• Cavity test
• 3.9 GHz effort
• Cryomodule fabrication and test
• ILC Civil and Site Development
• Industrialization
• Resources
• Summary of FY07 accomplishments
• FY08 Goals
• Conclusion

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Goals of Fermilabs ILC RD

• The overarching goals of Fermilabs ILC RD
• Establish credentials in ILC machine design
• Develop proficiency in SRF technology
• Become a trusted international partner
• such that FNAL becomes the preferred site to
  host the ILC.
• As part of the Global Design Effort (GDE) our
  goal is to help design the machine, estimate the
  cost, and gain international support.
• Fermilab ILC RD activities
• ILC Machine Design
• Development of SRF technology infrastructure
• Conventional Facility Site Studies for a US ILC
  site
• Industrialization Cost Reduction
• ILC Physics, Detector Design, and Detector RD
  (Marcels talk)

4
FNALs Role in the GDE

• In FY07 the focus of the worldwide effort on the
  International Linear Collider (ILC) was to
  complete the Reference Design Report (RDR) and
  cost estimate
• Draft delivered in Beijing in Feb 07 (Final in
  Korea in Aug)
• Fermilabs Role
• Large institutional contribution to this activity
• Many FNAL physicists and engineers involved
• Increased FNAL role via GDE leadership positions
• Current Lab effort
• 137 FTE on ILC machine design and SRF RD and
  infra
• 18 FTE on ILC Detector RD
• Growing engagement for Lab staff User community
• FNAL is poised to play an even larger role in the
  Engineering design of the ILC. Goal EDR by 2010

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FNALs role in the RDR/EDR

• Many FNAL Physicists and Engineers were in key
  RDR positions
• ILC Machine Area Leaders (typically 3 Ldrs
  1/region)
• Civil and Site Vic Kuchler
  Americas Ldr
• Main Linac Design N. Solyak 1 of 2
  Americas Ldrs
• Cryomodule H. Carter
  Americas Ldr
• Cryogenics system T. Peterson Americas
  Ldr
• Magnet systems J. Tompkins
  Americas Ldr
• Communications E. Clements Americas
  Ldr
• Design Cost Board (coordinated RDR and cost
  estimate)
• 9 member board P Garbincius (chair),
  R. Kephart (member)
• RDR Change Control Board (ILC baseline
  configuration control)
• 9 member board S. Mishra 1 of 3
  U.S. Members
• RD Board (Oversight of ILC RD program
• 11 member board M. Ross (Member)
• S0/S1/S2 task forces Ross, Nagaitsev,
  Kephart (Members)
• FNAL Hosts the GDE central office (admin support,
  etc)
• Nearly all have continuing roles in the
  Engineering Design organization
• M Ross 1 of 3 Project Managers , Jim Kerby 1
  of 3 lead engineers

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ILC Machine Design

• Accelerator physics
• Main Linac optics studies
• End-to-end simulation of the machine
• Study emittance preservation and vibration issues
• RF timing and control issues
• FNAL proposed the switch to a centrally sited
  circular Damping Ring vs. TESLA dog-bone DR
• Less expensive, less risk, fits on FNAL site
• Now the ILC baseline
• Engineering Design of Main Linac technical
  systems
• Cryogenics, RF, magnets, and controls systems
• Auxiliary systems water cooling, electrical,
  HVAC, etc
• Design of key Main Linac components
• Cryomodules, cavities, modulators, etc.
• The ILC is based on Superconducting Radio
  Frequency technology. A major focus has and will
  be SRF RD

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SRF Goals

• Demonstrate the baseline ILC Main Linac
  technology
• GDE S0 Cavity gradient of 35 MV/m good yield
• GDE S1 Cryomodules with average gradient gt 31.5
  MV/m
• GDE S2 One or more ILC rf unit with ILC beam
  parameters
• Key issue is variability in cavity performance
• Develop FNAL expertise in SRF technology
• Train FNAL staff
• RD to improve ILC performance, reduce cost
• Collaborate with U.S. International ILC
  partners
• Transfer SRF technology to U.S. industry
• Build FNAL SRF Infrastructure to support these
  activities
• DOE Review of FNAL SRF Infrastructure Plan in Feb
  07
• Report favorable ? proceeding with plan but at
  reduced funding

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Cavity/CM process and Testing
Plan Develop in labs then transfer technology to
industry
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SCRF Infrastructure

• High gradient cavities require extensive
  infrastructure
• Bare cavities
• Fabrication facilities ( e.g. Electron beam
  welders)
• Buffered Chemical Polish facilities ( BCP )
• Electro-polish facilities ( EP )
• Ultra clean H20 High Pressure Rinse systems
• Vertical Test System ( Cryogenics low power RF
  )
• Cavity Dressing Facilities (cryostat, tuner,
  coupler)
• Automatic welders, Class 10 clean room
• Horizontal Test System ( cryo and high power
  pulsed RF )
• String Assembly Facilities
• Large class 100 clean rooms, Large fixtures
• Class 10 enclosures for cavity inner connects
• Cryomodule test facilities
• Cryogenics, pulsed RF power, LLRF, controls,
  shielding, etc.
• Beam tests ? electron source (e.g. FNPL
  Photo-injector)
• Lots of but reuse of existing FNAL
  infrastructure reduces costs

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1.3GHz Cavity Fabrication

• Goals
• Acquire cavities to study surface processing
  (Qualified Vendor)
• Qualify U.S. cavity vendors to make ILC cavities
• Build cryomodules to train staff and test
  improvements
• Our progress depends on funding available to
  acquire cavities
• Delivered cavities (using all sources available)
• 4 from ACCEL (Processed and tested at Cornell,
  JLab)
• 4 from AES (Processing at Jlab, one cavity now at
  FNAL)
• 4 from Jlab ( 2 large grain, 2 fine grain)
• Additional cavities ordered from ACCEL (Qualified
  Vendor)
• For ILC surface processing studies and CM
  construction
• 8 ordered in FY06, 12 more in FY07 (DESY orders
  30-40 at a time!)
• Ability to order cavities is funding limited (
  80 K each )
• U.S. Vendors (trying to get them qualified)
• FY07 Ordered single cell cavities from AES,
  Roark, Niowave
• 6 additional nine-cells on order from AES

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FNAL Cavities Infrastructure
Cavity Tuning bead pull IB4 RF lab
ACCEL Cavity
800 C Bake IB4 Vacuum Oven
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U.S. Cavity Processing Test
Cavity Fabrication By Industry
Surface Processing _at_ Cornell
Surface Processing _at_ Jlab
Surface Processing _at_ ANL/FNAL
10/yr
50/yr
40/yr
Vertical Testing _at_ Jlab
Vertical Testing _at_ Cornell
Vertical Testing _at_ FNAL
Exists
ILC RD goals require new large processing
facility 100/yr
Cavity Dressing Horizontal Testing _at_ Fermilab
Developing
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EP and Vertical Test _at_ Jlab

• FNAL collaborates closely with Jlab on cavity
  processing
• Jlab modified existing infrastructure for
  Electropolish, High Pressure Rinse, and Vertical
  Test of ILC cavities
• Capable of gt 40 process and test cycles/yr
• Completed 32 in FY07

EP and Vertical Test at TJNL
Quench at 42 MV/M but back down to 32 MV/M
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EP Vertical Test Cornell
Vertical test
Vertical EP Infrastructure
HPR ( High Pressure Rinse)
ACCEL cavity EP Processed tested at Cornell
Limited by quench_at_ 30 MV/M

• New vertical EP RD infrastructure
• HPR Vertical Test of ILC cavities
• 3 ACCEL cavities processed 5, 8, 9
• 8 process and test cycles in FY07
• Gradients achieved 24-30 MV/M
• Limited by quench

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Cavity Process VTS Results
ILC Goal
ACCEL (Europe)
AES (U.S.)
Most cavities, esp. U.S. cavities are limited by
Quench vs. FE
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New ANL-FNAL Processing Facility

• Chemistry, Clean rooms, BCP,HPR
  state-of-the-art EP _at_ANL

New Clean Rooms
1st EP Aug 07 Single cell
New Chemistry Rooms EP
Operational Dec 07 50 EP cycles/yr
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New Vertical Test _at_ FNAL
Nine-cell Tesla-style cavity

• Recently commissioned (IB1)
• Existing 125W_at_ 1.8 K Cryogenic plant
• RF system in collaboration with Jlab
• Capable of testing 50 Cavities/yr
• Evolutionary upgrades
• Thermometry for 9-cells, 2 cavities at a time, 2
  top plates, Cryo upgrades
• Plan for two additional VTS cryostats
• Ultimate capacity 264 cavity tests/yr

Plan for 2 more VTS pits
VTS CryostatIB1
New RF Control Room
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Horizontal Test System

• Dressed cavities are tested with pulsed RF power
• 300 KW klystron modulator complete and tested
• Extensive MDB cryo modifications? 100 W _at_ 1.8 K
• HTS currently cold being commissioned with 1st
  cavity
• Serves as test bed for LLRF, tuner coupler
  studies
• Unique capability in Americas Goal 24 cavity
  tests/yr

1st 1.3 GHz Cavity in HTS Cryostat
HTS Cryostat Installed at MDB
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MDB Infrastructure
Cryogenics transfer lines in MDB
RF Power for HTS
300 KW RF Power for HTS
Capture Cavity-II
Large Vacuum Pump for 2K
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DESY Collaboration

• FNAL is building a 3.9 GHz 3rd Harmonic module
  for DESY
• Doubles light output of VUV-FEL
• Uses four 9 cell 3.9 GHz cavities
• Five cavities have been fabricated and have
  achieved gradient gt 20 MV/M gradient (Spec is gt
  13 MV/M)
• Serves as a pilot program for much of our ILC
  SCRF infrastructure (processing, vertical and
  horizontal test, cryomodule assembly, etc.)
• Expect to deliver the 3.9 GHz module to DESY in
  early 2008
• DESY and INFN have supplied Fermilab with all the
  parts for one 1.3 GHz (TTF 3) TESLA cryomodule
• Will be the 1st ILC type cryomodule built in the
  U.S.
• More on this in a minute

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ILC Cryomodule

• Cryomodules are complex
• Cavities made from pure Nb
• Smooth ultra clean surfaces
• Cavity handling is crucial
• Operate in 2K superfluid He
• 1200 parts!
• Cryomodules are expensive
• Single most expensive component of the ILC
• Must industrialize cavities, components, and
  maybe assembly
• Developing the extensive infrastructure to build
  and test CMs
• FNAL leads an international team working to
  improve the TESLA CM design for ILC (DESY, INFN,
  KEK, CERN, SLAC, India, etc )
• Plan to have an improved ILC design ready for
  bids by Mar 08

TTF Cryomodule
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ILC Type IV Design
Design Compete In Mar 08
2K Header and support
Vacuum Vessel
Radiation shields
Coupler
Cavity
2K He Vessel
Beam Axis
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Cryomodule Assembly Facility

• Goal Assemble RD Cryomodules
• Where MP9 and ICB buildings
• MP9 2500 ft2 clean room, Class 10/100
• Cavity dressing and string assembly
• ICB final cryomodule assembly
• Infrastructure
• Clean Rooms, Assembly Fixtures
• Clean Vacuum, gas, water Leak Check
• DESY Cryomodule kit being assembled now

ICB clean Final Assembly fixtures installed
Cavity string for 1st CM
String Assembly
MP9 Clean Room
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Cryomodule Plan

• 1st Cryomodule (2007)
• Assemble a TESLA TTF type III CM from DESY kit
  
• Cavities built and fully tested by DESY
• 2nd Cryomodule (2008)
• Also TTF type III cryomodule
• Cavities are processed and tested in the US
• Electropolished and tested at JLAB, Cornell, and
  ANL/FNAL
• Cryostat and cold mass from Zanon in Europe
• 3rd Cryomodule (2009)
• 1st type IV ILC cryomodule built anywhere
• Parts built in U.S. industry
• 4th-6th Cryomodules (2010-11)
• Build ILC RF unit in U.S.
• Transfer knowledge gained to Industry
• Develop, build test basic building blocks of
  the Main Linac to evaluate main linac cost and
  reliability issues

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RF Unit Test Facility (ILCTA_NM)

• Overall Plan
• Build an ILC RF Unit Test Facility at New Muon
  Lab Building (NML)
• One ILC RF Unit (3 Cryomodules)
• 10-MW RF System
• ILC-like Beam (3.2 nC/bunch _at_3 MHz, Up to 3000
  bunches _at_ 5Hz, 300-µm rms bunch length)
• Phase-1 (FY07 - FY08)
• Prepare Facility for Testing of First Cryomodule
  (CM1) without Beam
• Infrastructure, RF Power, controls
• Cryogenics (Refrigerator 1) gt reuse of existing
  TeV refrigerator
• Phase-2 3 (FY08 - FY10)
• Install Gun, Injector, CM2 and CM3, Test with
  Beam
• New RF Gun
• Move A0 Photo-Injector to NML and Install Test
  Beamlines
• Extend Building to fit Third Cryomodule
• Cryogenics (Refrigerator 2 (existing) and New
  Cryoplant-300W_at_2K)
• Upgrade RF System to 10 MW
• FY11 and beyond run ILC RF unit with full ILC
  parameters

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ILCTA_NM Layout
Existing Building
New ILC like tunnel
ILC RF unit
Diagnostics
Gun
3rd har
2nd ILC RF unit
CC I,II
Bunch Compressor
Laser
Test Area
New Building
Test Areas
RF Equipment

• 40-50 MeV Injector well characterized beam
• Low energy test area (e.g. 3.9 GHz Crab cavities)
  
• Twin tunnel design to allow 2nd RF unit and to
  study tunnel layout and maintenance issues
• New bldg for diagnostics AARD
• Also houses new cryo plant

new 300 W cryo plant
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Current Picture of NML Facility
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Refrigeration/controls, etc

• Cryogenic System
• Installed Gas Storage Tanks
• Refrigerator 1 (60W_at_1.8K)
• Installation complete
• 1st LHe last week !
• Cryo Distribution System
• Feed Can, Feed Cap, End Cap
• (in procurement stage)
• Control Room being Installed
• Instrumentation
• Wire Position Monitors for CM1
• Faraday Cup Fabrication
• RF Protection System
• Lots of progress but
• Concern 300 W refrigerator is expensive 2yr
  lead time item cannot order in FY08 or FY09 ?

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ILC Civil and Site Development

• With the GDE we are developing the ILC Civil
  Design
• Tunnel Design and Layout
• Convention Facilities design
• Cost and Schedule studies
• FY08 FNAL site specific design
• Optimal use of the large FNAL site
• Minimize cost and community impact
• Studies of actual machine layout
• Geological, environmental, land use, community
  issues
• Bring in large outside AE firms to consult

31 km
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Industrialization

• Principle goal of ILC industrialization is to
  establish in U.S. industry the capability and
  infrastructure to mass produce the components for
  the ILC
• Another important goal is cost reduction
• FY07 Activities
• Encourage support the LCFOA (meetings, etc)
• Industrial cost estimates in support of the RDR
• Development of U.S. Cavity vendors ( AES, Roark,
  Niowave )
• Development of Industrial Electropolishing (
  ABLE)
• Purchase of couplers from CPI, etc.
• FY08
• Qualify Industry for cavities CM parts
  production
• Qualify new U.S. vendors of high purity Nb
• Engage U.S. AE firms in FNAL site development
• Value engineering, RF equipment purchases, etc
• In the spring I charged a group to create an
  overall IC Industrialize plan (Ldrs Garbincius,
  Mishra). Preliminary report in Oct, final Jan 08
• Our ability to engage U.S. industry is limited by
  available funding, our own expertise, our SRF RD
  and test facilities, and industrial level of
  interest

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Resources (with overheads)

• FY08 ILC SRF growth is 1.9 lt inflation
• FY09 is better at 26 growth but still below
  FNALs understanding with OHEP
• Pier ILC line at 34 M all 35 M of the SRF
  line to FNAL
• Note The discrepancy in the SRF line may be
  because planned funds to SLAC, MSU, LANL are not
  included. However, even assuming these funds we
  are still missing 3-4M
• At least 7M less in FY09 than we expected

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Resources ( Direct)
FTE
64
120
155
158
173
Note 05-07 FTE numbers are from actual effort
reporting vs. SWF averages

• FY08 is flat in terms of workforce and MS
• Disappointing Does not allow us to build and
  operate needed SRF infrastructure in a timely way
  (NML refrigerator, EBW, CPF)
• Stagnation of Detector RD effort instead of FNAL
  leading LOIs
• Modest growth foreseen in FY09 guidancebut.
• We should all understand that these numbers are
  far short of those needed to support an early
  ( 2012 ) start of ILC

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Detector RD funding

• The ILC detector RD effort at the lab has nearly
  doubled each year. Funding in FY08 will be
  flat.
• Community calls for LOI's by the end of 2008
• As candidate lab to bid to host, we have the
  ambition to play a leading role in the
  preparation of the LOI's.
• FNAL established several core competencies,
  highly regarded by the world community need to
  grow these
• Many technologies for ILC detectors are novel and
  have to have system level tests.
• We provide funding to operate the test beam and
  provide infrastructure for these tests.
• The Projected FY08 detector budget is not
  compatible with our ambition and the goals of the
  WWS.

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Summary FY07 Accomplishments

• Large contribution to GDE RDR and cost estimate
• Completed Meson Detector Bldg 1.8 K cryogenic
  system
• 1st operation of the Capture Cavity II at high
  gradient (31 MV/M)
• With Jlab Cornell
• processed tested the first gt30 MV/ M cavities
  in the U.S.
• With ANL
• Completed new joint ANL/FNAL cavity processing
  facility
• Completion and first operation of a Vertical Test
  Stand in IB1
• Completion and first operation of a Horizontal
  Test Stand in MDB
• Completed Phase I Cryomodule Assembly Facility
  (MP9 IB1)
• Started assembly of the 1st U.S. built cryomodule
  in CAF
• TTF type III CM from DESY kit of parts
• Excellent progress on a 3.9 GHz Cryomodule for
  DESY
• Started construction of RF unit test facility at
  NML
• Initiated led a world wide collaboration on SRF
  materials

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Summary FY07 Accomplishments

• Conventional Facilities Development
• Major contributions to ILC CFS design
• Led the U.S. site specific design effort
• Signed MOUs with 15 national/international ILC
  institutions
• Many on SRF development
• Outreach
• Community Task Force, envoy program, single page
  handouts, web site, etc.
• Host GDE, ILC, industrialization, ILC schools,
  and SRF meetings
• Illinois
• Working with Illinois Dept of Commerce and
  Economic Development
• The Illinois Accelerator Research Center, a new
  35 M FNAL building dedicated to education, SRF
  development industrialization is in Illinois
  capitol bill that awaits passage
• Program Management
• Extensive financial tracking tools in place for
  ILC/SRF effort
• Started to develop EDR schedules and trackable
  RD milestones

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Conclusions

• In FY07 made major contributions to the RDR
• Large role in GDE, machine design, and
  engineering
• Significant progress on FNAL SRF infrastructure
• Many new facilities turning on in FY07
• But pace of progress is limited by funds
• Key long term items are not adequately funded
  (new NML refrigerator, EBW, new large cavity
  processing facility, Detector RD etc)
• Developing extensive collaborative connections
  with the goal of becoming a trusted international
  partner
• Extensive CFS work in progress to develop ILC
  design and study FNAL as a possible ILC host site
• Growing staff involvement and outreach efforts
• Expect FNAL to play a large role in the EDR

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FY08 Goals and Milestones

• Major contributions to the EDR effort
• Continue to expand collaborative work on ILC/SRF
• Complete Commissioning VTS HTS Oct 07
• New HPR system complete at ANL Dec
  07
• 1st 9-cell operation of ANL EP system
  Jan 08
• Process test 25 cavities _at_ Jlab, Cornell,
  ANL/FNAL
• New 9-cell thermometry system for VTS Jan
  08
• Start move of A0 Photoinjector to NML Feb
  08
• Type IV CM parts out for bid
  Mar 08
• Ship 3.9 GHz CM to DESY
  Apr 08
• Finish design FNAL processing facility Jun
  08
• Operation of 1st CM in NML
  Aug 08
• Increased effort on industrialization