MQXF support structure An extension of LARP experience Helene Felice MQXF Design Review December 10...

MQXF support structureAn extension of LARP experience

Helene Felice

MQXF Design Review December 10th to 12th , 2014

CERN

LQLongQuadrupoleLQS01a-b/02/03

LRLong RacetrackLRS01-02

HQHigh-field QuadrupoleHQ01a-b-c-d-eHQ02a-b / HQ03a

Snapshot of LARP support structure experience

12/10/2014Helene Felice 2

Length

Time

2004

2014

2005

2006

2007

2008

2009

2010

2011

2012

2013

0.3 m 1 m 3.6-3.7 m

SQSubscale quad

TQTechnology QuadrupoleTQS01/02a-b-c/03a-b-c-d

LRLong RacetrackLRS01-02Length demonstration

LQLongQuadrupoleLQS01a-b/02/03Some accelerator quality featuresLength with cos2qAccommodating variability in coil dimension

HQHigh-field QuadrupoleHQ01a-b-c-d-eHQ02a-b / HQ03aAccelerator quality featuresMechanical alignment

Step-by-step technology demonstration


Length

Time

2004

2014

2005

2006

2007

2008

2009

2010

2011

2012

2013

0.3 m 1 m 3.6-3.7 m

SQSubscale quadConcept

TQTechnology QuadrupoleTQS01/02a-b-c/03a-b-c-dConcept on cos2qTechnology selection Scale-up & design optimization

LRLong RacetrackLRS01-02Length demonstration

LQLongQuadrupoleLQS01a-b/02/03Some accelerator quality featuresLength with cos2qAccommodating variability in coil dimension

HQHigh-field QuadrupoleHQ01a-b-c-d-eHQ02a-b / HQ03aAccelerator quality featuresMechanical alignmentHigh stress regime

Exploration of the stress limits


Length

Time

2004

2014

2005

2006

2007

2008

2009

2010

2011

2012

2013

0.3 m 1 m 3.6-3.7 m

SQSubscale quadConcept

TQTechnology QuadrupoleTQS01/02a-b-c/03a-b-c-dConcept on cos2qTechnology selectionUltimate stress exploration

Scale-up & design optimization

Outline

• Shell-based support structure concept• Exploring the limits

– TQ high stress • Step-by-step technology demonstration

– Design optimization– Length

• QXF support structure– Main features


Helene Felice 6

Shell-based support structureMotivation and concept

12/10/2014

• Shell-based support structure often referred as “bladder and keys” structuredeveloped at LBNL for strain sensitive material

coil

pad

shell

Shell-based support structure Supporting tools


• Numerical tools

• Instrumentation

• Assembly based on analysis• Control of the pre-stress level• Constant feedback between

SG measurements and model

Helene Felice 8

Shell-based support structureConcept

12/10/2014


Helene Felice 9


12/10/2014

Displacement scaling 30


Inflated Bladders

Bladder

Helene Felice 10


12/10/2014



Shimming of the load leys

Keys

Bladder

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12/10/2014



Cool-down

Cool-down

Keys

Bladder

Helene Felice 12


12/10/2014


Energized


Lorentz forces

Cool-down

Keys

Bladder

cold

Room temperature

Collaring process- Courtesy of Paolo Ferracin

With shell structure

Support structure allowing fine tuning of the

Shell-based support structureKey features

• Gradual application of the preload: no overshoot

• Tunable preload– During assembly– In between tests

• Reversible assembly process– Allowing replacement of a defective coil if needed

• Correlation between models and strain gauges measurements


Outline






Stress limits: defining an acceptable rangeTQS03 program


CONDUCTOR• OST RRP 108/127 strand• High RRR• 54 % Cu fraction• Jc (12T, 4.3 K) 2770 A/mm2

• 27 strands cable• 1.26 mm mid-thickness bare• 10 mm width bare• 0.125 mm insulation

TQS03parameters

4.3 K 1.9 K

Iss (kA) 13.2 14.5

Bpeak ss (T) 12 13

Gss (T/m) 234 254

4 tests: TQS03 a, b, c and d

• performed with variable pre-stress• TQS03a: 120 MPa• TQS03b: 160 MPa• TQS03c : 200 Mpa• TQS03d: 120 MPa

• supported by ANSYS analysis


Strain gauges location

In boxes: sig theta measured

Add predicted on box

-1500

-1000

-500

0

500

1000

1500

2000

2500

3000

300K 4.2 K 300K 4.2 K 300K 4.2 K 300K 4.2 K

TQS03a TQS03b TQS03c TQS03d

e q(me)

shell T meas

Pole T meas

shell T ANSYS

Pole T ANSYS

-160 MPa

-120 MPa-190 MPa

-110 MPa

200MPa180MPa

160MPa 160MPa

Good agreement between measurements and ANSYS prediction


78

80

82

84

86

88

90

92

94

96

98

100Fr

acti

on o

f I ss(%

)

TQS03a

TQS03b

TQS03c

TQS03d

4.3 K 1.9 K 4.3 K

93 %

91 %

88 %

88 %

~ 11.6 / 12.8 kA

• Only 5 % degradation from TQS03a to TQS03c• TQS03d did not recover => Permanent

degradation

~ 12 / 13.2 kA

~ 12.3 / 13.5 kA

Helene Felice 18

Strain gauge data during excitation

12/10/2014

Strain gauge

• conclusion

TQS03a

TQS03b

TQS03cPreload increase

Preload increase

Correlation between preload levels and magnet performance allowed the definition of a safe range of transverse stress in Nb3Sn coils

Outline






From TQ to HQDesign optimization


TQ LQ

• No alignment features

Plot of stress along the length

• Optimization of the design• load key positon• Pad extremity in

stainless steel to lower peak field in the end

• Implementation of alignment features from pad to shell

From TQ to HQDesign optimization: key position optimization


TQ - 90 mm aperture- 12 T peak field - 240 T/m

- Fq Layer 1 = -1.5 MN/m- Fq Layer 2 = -1.02 MN/m

LQ- 90 mm aperture- 12 T peak field - 240 T/m


-100 MPa

-187 MPa

-85 MPa

-171 MPa

Key

optimization

=> Optimization of the key position to improve stress distribution

20 MPa 20 MPa

From TQ to HQDesign optimization


TQ LQ HQ

• No alignment features

• Cross-section optimization considering force distribution between layers

• Alignment features between coil and pads: aluminum collars and key

• Optimization of the design• load key positon• Pad extremity in

stainless steel to lower peak field in the end

• Implementation of alignment features from pad to shell

From TQ to HQDesign optimization: key position optimization


TQ - 90 mm aperture- 12 T peak field at 4.3 K- 240 T/m


LQ- 90 mm aperture- 12 T peak field at 4.3 K- 240 T/m


HQ - 120 mm aperture- 14 T peak field at 4.3 K- 200 T/m

- Fq Layer 1 = - 2.1 MN/m- Fq Layer 2 = - 2.6 MN/m

-100 MPa

-187 MPa

-85 MPa

-171 MPa

MPa

MPa

Xsection

optimizationKey

optimization

=> Improvement of the cross-section to avoid layer 2 overloading

20 MPa 20 MPa MPa


Stress in HQ


Adresses:- Stress distribution

- 2D and 3D- Pad ss and iron- Ground for MQXF stress level

Outline



– Design Optimization– Length



1st long shell based structure:the Long Racetrack LR


• LRS01: full length shell• Friction limits the shell contractions

• Central part locked• Strain at 4.5 K consistent with 0.2 friction

model results• During excitation e.m. forces induced

slippage

Magnet parameters

( )( )zE ee

qq

21

Helene Felice

Impact of shell segmentation

12/10/2014 #28

• LRS01– High meas. axial strain meas.– Effect on azimuthal stress

• LRS02 (with segmented shell) – Reduced axial strain

LRS

LQS

LRS01

LRS02

( )( )zE ee

qq

21

Helene Felice 29

Length demonstration on a cos2 q magnet:the Long Quad LQ

12/10/2014

• 90 mm aperture coils with Ti poles • Iron pads, masters, yokes, Al shell• Pre-load with bladders and keys• TQ coil scale-up

• LQS01-2 Short-sample limits (4.5 K – 1.9 K)– Gss: 240 T/m – 267 T/m

– Iss: 13.8 kA – 15.4 kA– Peak field: 12.3 T - 13.6 T

• LQS03 Short sample limit

– -Gss: 227 T/m – 250 T/m

– Iss: 12.9 kA – 14.4 kA

– Peak field: 11.5 T - 12.8 T

• End support: plate and rods• Magnet/coil length: 3.7/3.4 m

30

Preload for 240 T/m: 471 kNsz and ez at 300 K- target (3D): +88 Mpa (178 kN)

+455 mesz and ez at 4.3 K- target (3D): + 239 MPa + 1138 me

Rod

0

10

20

30

40

50

60

70

-0.2 0 0.2 0.4 0.6 0.8 1

End

cont

act p

ress

ure

(MPa

)

Fem/Fem_240T/m

293 K

End

Con

tact

pr

essu

re (

Mpa

)

Preload for 260 T/msq and eq at 300 K - target (3D): -82 MPa

-580 mesq and eq at 4.3 K - target (3D): -157 MPa -1031 me

s q (MPa)

Pole

Mechanical AnalysisTypical Stress distribution

12/10/2014Helene Felice

Preload for 260 T/msq and eq at 300 K- target (3D): + 56 MPa

+ 750 mesq and eq at 4.3 K- target (3D): + 183 MPa +2080 me

s q (MPa)

Shell

NO gap

-198-180-162-143-125-107-88-70-51-33

149156163170177184191198208212

Axial strain in shell


Helene Felice 32

Production readiness:Accommodating coil size variation

12/10/2014

Expected

measured

shell Strain Gauge

coil Strain Gauge

Nominal

padPole StrainGauge

LQS01a

Nominal Oversized

padPole StrainGauge

92 % at 4.5 K

LQS01aLQS01b

Outline



– Alignment features– Length



From LARP to MQXF


MQXF support structure overview


• Show how the key features described before are found in MQXF support structure design

• Point to Mariusz’s talk

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