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Appendix:TF SULTAN Sample Assembly

Procedure at CRPP

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Conductors and empty tubes are

inspected upon delivery at CRPP.

(Courtesy

of P. Bruzzone,

CRPP)

Conductor Inspection

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Whenever required, the conductors are straightened using a jack (asin the case of TFJA4).

(Courtesy

of P. Bruzzone,

CRPP)

Conductor Straightening

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The jacket is dismantled from both ends of the conductor section (420mm at the upper termination side and 440 mm at the bottom joint side).

Dismantling procedure starts with a radial indent by lathing machine,

followed by two longitudinal milling passes. The two jacket halves are pulled apart with the help of welded grips once

the thickness of the jacket is milled down to few hundredths of millimetre.

(Courtesy

of P. Bruzzone,

CRPP)

Jacket Dismantling

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The outer wrap is removed anda clamp is applied to the end ofthe cable to prevent untwisting.

The sub-cable wraps are cut atthe cable surface and pulled outfrom inside the cable by slightlyuntwisting the cable.

Cr plating is removed by dippingthe cable for 3 min in a HClsolution placed in an ultrasound

bath; nitrogen gas is blown fromthe other end to preventpenetration of corrosive vaporinto the conductor.

The solution turns dark blue andthe cable is rinsed 3 times inwater in the ultra-sound bath.

(Courtesy of P. Bruzzone, CRPP)

Un-Wrapping & Cr Plating Removal

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(Courtesy of P. Bruzzone, CRPP)

At the upper crimping rings, a 100 mm long steel pipe (welded shut) is placed bythe same method. The distance between the jacket edge and the start of the plug is 19 mm.

A 855 mm long steel pipe,welded shut at one end andwith a thread machined at the

other end, is placed at the HFZand lower crimping rings by athreaded rod; once theposition is reached, the

threaded rod is removed.

Central Channel Plugging

The central channel is plugged underneath the crimping rings (to prevent a localcollapse of the central spiral) and in the High Field Zone (to force the helium inthe bundle region and restrain the temperature gradient over the cable crosssection), but it must not be plugged in the termination sections where the bundle

region is solder filled.

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The crimping rings are compacted.

(Courtesy of P. Bruzzone, CRPP)

Crimping Rings

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A pre-fabricated copper sleeve with electron beam welded stainless

steel end caps is carefully slid over the cable.

(Courtesy of P. Bruzzone,CRPP)

Cu Sleeve Insertion

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The assembly is compacted in a crimping device.

Opposite to a swaging device with rotating heads, the crimping

device causes negligible elongation to the termination, but thestepwise action of the crimping device leaves imprints on the coppersurface, which is no longer smooth and perfectly round.

During compaction, the inner cable diameter is reduced from

nominal to 38 mm; assuming that the central channel is notreduced, the void fraction in the annular region changes from theoriginal ~29% to ~23%.

(Courtesy of P. Bruzzone, CRPP)

Cu Sleeve Compaction

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The steel end cap of the sleeve is vacuum tight welded to thejacket.

(Courtesy of P. Bruzzone, CRPP)

Cu Sleeve Welding

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To improve quality of the sleeve surface and allow a good solderingwith the matching parts after the heat treatment, the termination is

lathed to remove the imprints of the crimping machine.

(Courtesy of P. Bruzzone, CRPP)

Cu Sleeve Lathing

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Heat treatment is carriedout in a Thermcraft tubefurnace in vacuum, with a

residual pressure smallerthan 3.8 10-6 mbar. During the entire HT, a

flow of high-purity argon

(0.05 li/min) purges thesample of any developinggases or fumes.

The furnace control system

regulates the temperatureof the inside furnace wall.

The furnace temperatureand the temperature of 5

sensors attached to theconductors are recorded ina PC.

(Courtesy of

P. Bruzzone, CRPP)

Heat Treatment

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A siphon is pre-assembled by a steel cap, a 500 mmlong Teflon rod (to keep the central channel freeduring solder filling) and a copper pipe.

First the copper pipe is brazed to the steel cap, then,the Teflon is squeezed into the hole of the steel cap.

Finally, the assembled siphon is welded to the steelend cap of the sample termination.

(Courtesy of

P. Bruzzone, CRPP)

Siphon Assembly

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A hole is drilled in the steel part of the termination welded to the jacket

as an outlet of the cooling gas injected during flux and solder filling fromthe opposite side of the conductor.

(Courtesy ofP. Bruzzone, CRPP)

Outlet Hole Drilling

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The conductor is lowered into the fluxagent placed in a retort in an ultra soundsbath.

(Courtesy ofP. Bruzzone, CRPP)

Solder Filling (1/4)

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The termination and its siphon pipe arelowered into a bath of PbSn alloy, heated at260 C (above the melting temperature of

SnAg5 used for solder filling). The PbSn bath is in an aluminum container

sandwiched between two heaters,

(Courtesy of

P. Bruzzone, CRPP)

Solder Filling (2/4)

S ld illi (3/ )

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SnAg rods are inserted and melted in thecopper siphon till the siphon is full.

(Courtesy of

P. Bruzzone, CRPP)

Solder Filling (3/4)

S ld Filli (4/4)

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(Courtesy ofP. Bruzzone, CRPP)

Once the filling is completed, thetermination is lifted from the bath.

In the case of TFJA4, the terminations

stayed ~8 minutes in the bath and theamount of SnAg solder, including the fillingof the siphon pipe, was 1450/1490 g for the upper termination, 1064/901 g for the lower termination.

Solder Filling (4/4)

Fi l P (1/2)

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(Courtesy of

P. Bruzzone, CRPP)

After solidification of the solder,the copper pipe is cut away andthe solder filled steel cap is

carefully sawed (without cuttingthe Teflon rod).

The Teflon rod is pulled out lettingfree the central channel in the

termination.

Final Prep (1/2)

Fi l P (2/2)

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The solder is removedmechanically from the end oftermination to prepare the welding

of the inlet and outlet coolingpipes.

The temporary venting hole iswelded shut.

(Courtesy of

P. Bruzzone, CRPP)

Final Prep (2/2)

D t ti E i ti

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Effectiveness of solder filling procedure was checked by destructiveexamination of a solder filled termination.

(Courtesy of

P. Bruzzone, CRPP)

Destructive Examination

Inst mentation

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Arrays of voltage taps are welded to thejacket.

Temperature sensors are attached tomachined flats on the conductor jacket.

(Courtesy of P. Bruzzone, CRPP)

Instrumentation

Upper Termination Assembly

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A copper plate issolder to each of theupper terminations tobuild the flat contactsurface to SULTANtransformer.

Soldering is done at190 C with SnPbeutectic alloy toprevent melting of

the SnAg solderinside thetermination.

(Courtesy of P. Bruzzone, CRPP)

Upper Termination Assembly

Bottom Joint Assembly

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The bottom joint is made bysoldering a copper saddle toboth lower terminations.

As for the upperterminations, SnPb is used at190 C to prevent melting ofthe solder inside thetermination.

The joint assembly issandwiched between twoheaters, with aluminiummatching parts to fit the flatheaters to the roundtermination.

After completing the

soldering, a steel clamp isapplied and the cooling pipesare welded.

(Courtesy ofP. Bruzzone,

CRPP)

Bottom Joint Assembly

Overall Assembly (1/3)

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(Courtesy of

P. Bruzzone,

CRPP)

After completion of termination andjoints, the assembled conductors arebolted into a segmented steel clamp.

Electrical insulation between clampand conductors is provided by 1-mm-thick glass-epoxy half shellsmatching the diameters of the two

conductors. A segmented glass epoxy saddle

piece separate the two conductors.

Overall Assembly (1/3)

Overall Assembly (2/3)

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(Courtesy of P. Bruzzone, CRPP)

The repulsive force between the two conductors at high field isestimated up to 1 MN/m and is reacted by M10 bolts, spaced by 50

mm (2.5 t/bolt). The bolts are pre-loaded with only 5 Nm to prevent deformation of the

round conductor.

Upper Termination

Bottom Joint

Clamp

Overall Assembly (2/3)

Overall Assembly (3/3)

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Upper TerminationBottom Joint

Fully assembledsample

seen fromBottom Joint

(Courtesy ofP. Bruzzone,

CRPP)

Overall Assembly (3/3)

Connection to TRAFO

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Indium wires are deposited onto the faces of the upper terminations,which are inserted and bolted to the Trafo terminations.

(Courtesy of

P. Bruzzone,CRPP)

Connection to TRAFO

Installation in SULTAN

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(Courtesy of

P. Bruzzone,CRPP)

Finally, the TRAFO/sample assembly is inserted into SULTAN.

Installation in SULTAN