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Introduction Why copper Fabrication steps Shaping of half-cells and extremities Dimensional control half-cells Welding tests Dimensional control dumb-bells Extremities RF measurements Shape accuracy by CMM vs. RF Trimming half-cells Welding dumb-bells RF measurements of dumb-bells - PowerPoint PPT Presentation
Citation preview
N. Valverde 1
Manufacturing parameters for β=1 cavity mock-up
Nuria Valverde on behalf of the
SPL team
CERN, 8 Dec. 2011
N. Valverde 2
Introduction Why copper Fabrication steps Shaping of half-cells and extremities Dimensional control half-cells Welding tests Dimensional control dumb-bells Extremities RF measurements Shape accuracy by CMM vs. RF Trimming half-cells Welding dumb-bells RF measurements of dumb-bells Trimming dumb-bells Planning Conclusion
Ove
rvie
w
N. Valverde 3
Introduction
Two copper cavities(mock-up) are under fabrication:-To learn from the fabrication of the copper cavity for the niobium cavity. -To carry out RF measurements on the dumb-bells and complete cavity with the HOM.
-For surface treatment purposes
Copp
er
cavi
ty
N. Valverde 4
Why copper?
• Similar mechanical properties
• Good electrical conductor• Less expensive
• OFE Copper: 17 €/kg • Niobium: 470 €/kg
Copp
er
cavi
ty Cu-OFE (annealed)
Niobium RRR>300
Young’s modulus (Gpa) 122-128 100-110
Yield strength (Mpa) 50-70 50-100
Elongation (%) 47-50 40-50
N. Valverde
SpinningMtlg controlMachinningRF measurementDegreasing +Cp
Spinning
Machining – Welding preparation (Iris & rings)
RF measurementDegreasing
+Cp
Dumb-bell assemblyDegreasing+CpStiffening rings assemblyRF measurementCutting dumb-bell lengthRF measurementDegreasing+ Cp
Nb
EBWEBWEBWDegreasing
+Cp
Trimming cells length
RF measurement
RF measurementDegreasing
+Cp
HALF
- CEL
LDU
MB-
BELL
Metrology control
Fabrication steps
N. Valverde
SpinningExtrusionMachinningDegreasing + Cp
SS Flange-NicklingAssembly flange + bushingMachiningDegreasing +Cp
Spinning
Extrusion
Machining
BRAZING
Brazing
Degreasing +Cp
Machining
Degreasing +Cp
EBWEBW
Nickeling
Nickeling
Cu
SS
BIG
FLAN
GE SS Flange-NicklingAssembly flange + bushingMachiningDegreasing +Cp
Nickeling
Nickeling
Brazing
Machining
Degreasing +Cp
Cu
SS
SMAL
L FL
ANGE
S
2x
Fabrication steps
N. Valverde
Assembly extremities & dumbbells
EBW
RF measurement
Cutting cells length
Degreasing +Cp
Assembly extremities & half- cellRF measurementMachinningRF measurement
Tack-weld- EBW EBW
Tack-weld- EBW EBW
EBW
Tack-weld- EBW
Tack-weld- EBW EBW
Fabrication steps
N. Valverde 8
Shaping of half-cells & extremitiesH
alf-
cells
&
extr
emit
ies
Fabrication of half-cells and extremities by spinning. Subcontracted to Heggli
Dimensional controlThe average shape accuracy achieved is ± 0.150 mm
N. Valverde 9
Dimensional controlCo
pper
hal
f-ce
lls
The average shape accuracy achieved is ± 0.150 mmThe best half cell: shape accuracy ± 0.119 mm
Dimensional control by CMM
N. Valverde 10
Welding testEB welding of two half-cells to study the welding parameters and the shrinkage of the iris weld.
Copp
er d
umb-
bell
N. Valverde 11
Welding test II
EB welding of stiffening ring to dumb-bell to study the welding parameters and the welding shrinkage.
Copp
er d
umb-
bell
Next step is to weld two dumb-bells by the equator
N. Valverde 12
Welding test IICo
pper
dum
b-be
ll
Before welding After welding
Thanks to S.MARCUZZI
Shape accuracy by CMM
Dimensional control
N. Valverde 13
Extremities•Extremities fabricated in one piece by spinning and nozzle necks made by extrusion to minimize the welding distortions.•SS (316LN) Conflat flanges brazed to the copper tubes.
Extr
emit
ies
N. Valverde 14
Rf measurements of half-cells
Measurement setup
Hal
f-ce
lls
Results on cavity simulations and measurements presentation tomorrow by S. Mikulas
N. Valverde 15
Shape accuracy by CMM vs RFH
alf-
cells
Shape accuracy of middle half-cells
Shape accuracy by CMMShape accuracy by RF
Freq
uenc
y de
viati
on M
Hz
Results on cavity simulations and measurements presentation tomorrow by S. Mikulas
Shap
e ac
cura
cy m
m
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 190.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Shape accuracy by CMM vs RF
N. Valverde 16
Trimming half-cellsExtra-length has been considered on iris (2.5 mm) and equator (5mm).
Hal
f-ce
lls
2.5 mm
5 mmDesign of central half-cell copper cavity
N. Valverde 17
According to the shrinkage measured during the welding test we have machined 2.25 mm on the iris of each half-cell.
Hal
f-ce
llsTrimming half-cells
Trimming of central half-cell
N. Valverde 18
Welding dumb-bells
After trimming, 8 dumb-bells have been welded.
Dum
b-be
lls
N. Valverde 19
RF measurements of dumb-bellsD
umb-
bells
Dumbbell measurements presentation tomorrow by N. Schwerg
N. Valverde 20
Trimming dumb-bells• In order to achieve the final cavity with the right
frequency and a length within the tolerances the dumb-bells shall be trimmed at the equator to a specific length (to be calculated for each dumb-bell).– Trimming at the equator increases the frequency– Compression of the final cavity by tuning decreases the
frequency – Elongation of the final cavity by tuning increases the
frequency.
Playing with these factors we have to obtain the right frequency at the right length.
Dum
b-be
lls
N. Valverde 21
Planning
Preliminary planning for two copper cavities
EB welding
RF measurements
Machining
Degreasing, etching
N. Valverde 22
Conclusion
• Two copper cavities under fabrication. • We learn from the fabrication of copper
cavities.• Many fabrication steps will be retained for the
fabrication of the niobium cavity.• Assembly tooling of copper has been validated
and it will be used for the niobium as well.• One copper monocell β=0.65 to be fabricated
next year.
Conc
lusi
on
N. Valverde 23
FIN
Thanks for your attention!!