LARP Collaboration Meeting TQS01 - Progress

Shlomo Caspi

Lawrence Berkeley National Laboratory

April 26-28, 2006

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Outline

• TQS01 - Construction

• Design and Analysis

• Preliminary test results

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Statement of work – TQS01

One of the main objectives:

• Compare the magnet performance with the Compare the magnet performance with the design parametersdesign parameters.

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TQS01 Main Features

• A 2 layers Nb3Sn Quadrupole

• A 10mm wide 27 strand cable. (0.7mm MJR strand)

• Short sample 4.2K (B,G,I) : 11.2T, 220T/m, 12.3kA

• Accumulated Lorentz stress : S_theta=-123MPa

• Accumulated axial force (4 quadrants) : F_z=350kN

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2 layers

FillerKeys

4 pads

Bladder

Yoke

Aluminum shell

TQS01

•No collarsNo collars•BladdersBladders for coil azimuthal pre-stress for coil azimuthal pre-stress

B ~ 12 T, stress: 150 MPa, total axial force = 350 kN

The structure and assembly is different from any previous magnet of this kind

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TQS01 – Construction

• Coil winding• Coil reaction• Instrumentation• Impregnation• Coil sub-assembly• Structure sub-assembly• Final assembly and pre-stress

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Coil winding at FNAL

• A double layer

• Bronze island and end spacers

• Layer 1 wound on a mandrel and cured using a binder.

• Layer 2 wound on top of layer 1 and then cured.

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Coils Shipped to LBNL

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Prepare for Reaction

Two coils reacted together

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Into Reaction Oven

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Reaction Cycle (Coils 7 and 8)

•72 hr at 210 C

•48 hr at 400 C

•48 hr at 640 C

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Post-Reaction

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Coil - Instrumentation

Voltage tap

Strain gauge

Inner layer trace

Strain gauges and voltage tap attached to trace

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Ready for Impregnation

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Impregnation

Coil placed into impregnation

chamber

Controller

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Impregnated Coils

Strain gauges placed on layer 1 island

Voltage traces

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Coil-pack sub-assembly

Coil-pack is a sub-assembly of coils pads and fillers

Coil Pack is assembled, squared and bolted.

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Structure sub-assembly, shell, yoke and intermediate gap keys

• 20” OD x 18” ID x 40”long, 6061-T6 aluminum shell, precision machined.

• 1018 steel yoke laminations, 2”-thick

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SHELL & YOKE SUB-ASSEMBLY,cont’d

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Final assembly

• Mating the coil pack with the shell & yoke sub-assembly.

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End Support

bullets

End plate (89 mm thick)

Axial Aluminum rods (44 mm dia.)

Strain gauges

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End plates assembly

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Axial load components

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Axial Pre-stress

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Axial Pre-stress, cont’d

• 25 -Ton hydraulic actuator (9500 psi)

• Axial Loading Rig

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Azimuthal pre-stress (bladder operation)

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Complete assembly – return end

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End splices

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End splices (pizza box)

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TQS01 lowered into cryostate

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Outline

• TQS01 – Construction

• TQS01 – Design and AnalysisTQS01 – Design and Analysis

• TQS01 – Peliminary results (cool-down)

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Integrated analysis and simulations

CAD (engineering)

FEM (magnetic)

FEM structure multi-physics

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3D mechanical analysis: Lorentz forces

• ANSYS• x, y, and z coordinates of

each coil element center

• OPERA• Computation of J x B

(N/mm3) at each x, y, and z coordinate

• ANSYS• Computation of J x B Vel

(N)• Final force applied to each

coil node

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TOSCA

Layer 1 |B|=12.15T in SS

Layer 2 |B|=12.0T END

I=13.5kA,1.9K

Maximum field:

Layer 1 - straight section

Layer 2 - end

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Structural Analysis - ANSYS

Steps:

Assembly.Assembly.

Cool-down.Cool-down.

Lorentz forces 10-15 kALorentz forces 10-15 kA

Load Cases:• Combinations of azimuthal and axial pre-stress• Model with and without friction or glued• Blocked turns and individual turns

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ANSYS model – straight section

Rule 1 - No azimuthalRule 1 - No azimuthal separation at the poleseparation at the pole

1

2

3

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ANSYS model – coil ends

Island End-shoeSpacer

Rule 2 - No axial separation in the endRule 2 - No axial separation in the end

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Structure – Shell - azimuthal

Shell and yoke mu=0.6, all other

surfaces with friction, mu=0.2

SS 4.2K SS 1.8K

Low assembly pre-stress

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Structure – Axial rods

Low assembly pre-stress

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Azimuthal stress in layer 1 (with friction)

± range

Short sample 4.2K

Short sample 1.9K

4.2 K

14kA

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Training Mechanism

Straight sectionStraight section

• Axial tensile strain in the pole island held by friction releases when the coil pulls away due to insufficient azimuthal pre-stress.

End sectionEnd section

• Sliding and tarring between the coil and the island due to insufficient axial pre-stress.

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Island axial strain- straight section

abrupt or slow

release of strain

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release of axial strain

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Ends and axial Lorentz Force

Lorentz axial force 351/413 (kN)

Applied axial force 800 (kN)

(with friction)

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0 friction, limited axial load

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Island axial displacements- end section

170 µmIsland

displacement

(with friction)

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Outline

• TQS01 – Construction

• TQS01 – Design and Analysis

• TQS01 – Preliminary test resultsTQS01 – Preliminary test results

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Strain Measurements

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Cool-down

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Rods – measured cool-down stress

4.3K4.3K

200K200K

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Shell – measured cool-down stress

E

1 2 z

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Shell – measured cool-down stress

4.3K4.3K

200K200K

E

1 2 z

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Island – measured cool-down stress

•Axial tensile stress

•Compressive azimuthal stress

E

1 2 z

4.3K4.3K

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Ratcheting During Cool-Down

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Shell ratcheting during cool-down

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Coil ratcheting during cool-down

ratcheting in theta

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Coil ratcheting during cool-down

Minimum /no ratcheting in Z

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Excitation

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TQS01 4.45k Training

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Layer 1 center island

Lay1-Lay2 ramp

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Coil Center Details

SG-Z SG-Theta

Start of L1-L2 rampIsland discontinuity

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Coil End Details

SG-Z

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Island azimuthal strain during excitation

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Island strain in θ, magnet center

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Island strain in Z, magnet center

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Island axial strain (center)

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Island Stress

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Island Stress over many quenches

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Island strain in Z, lead end

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Island axial strain (end)

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Island axial strain (end)

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StructureShell in θ, z

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Shell azimuthal strain

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Shell axial strain

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Shell stress

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Shell stress

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StructureRods in z

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Rods Stress

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Rods Stress

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Summary

• The most “engineered” magnet we ever built.

• Analyzed every component from assembly through cool-down and excitation and pushed Nb3Sn technological to new limits.

The design expectations are:

• Reach short sample prediction (field, current, stress)

• Get there with minimum training

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Summary …

• First quench – Q1 at 80% of ss (176 T/m)

• Plateau – Q12 at 86% (190 T/m)

• Thermal cycle on TQS01

• Data reduction and analysis:• Strain gauge measurements• Quench locations• Refine ANSYS analysis

• If evidence suggests a problem in coil 6 ramp area:• Replace coil 6 with spare and retest• Section ramp area