T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 1 of 17

SRF Design, Analysis, and Prototyping at AES

Heavy Ion SRF Activites at Advanced Energy Systems, Inc.

John W. Rathke, Chief EngineerAdvanced Energy Systems, Inc.

27 Industrial Blvd, Unit EMedford, NY 11763 USA

Phone: 1-631-345-6264x110Fax: 1-631-345-0458

www.aesys.net

HPSL Conference

24 May 2005

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 2 of 17

SRF Design, Analysis, and Prototyping at AES

 

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 3 of 17

SRF Design, Analysis, and Prototyping at AES

AES Manufacturing

Machine Tools HAAS VF-8/50 3 Axis CNC Mill, 64”x40”x30” HAAS VF-5/50 3 Axis CNC Mill, 50”x26”x26” Okuma 3 Axis CNC Mill, 40”x20”x20” HAAS SL-40 CNC Lathe, 40”x 44” Length of

turn Okuma CNC Lathe, 17.7” x 20” Length of turn HAAS TL-3 Hybrid Manual/CNC Lathe (2) Series 1 Bridgeport Mills - 30” Travel Harrison Gap Bed Lathe 16.5” x 40” Length of

turn (24” w/ gap removed) Hardinge Tool Room Lathe 6” x 15” Length of

turn

Sheet Metal – Metal Forming LUNA Plate Bending Roller – 50” x 10 ga. Niagara Power Shear - 10 gage x 48 in. Whitey Metal Tool Sheet Metal Notcher 20 in. Hand Roller LVD Power Brake - ¾ Mild Steel x 48 in. Leaf Brake 16 Gage x 24 in. KR Wilson - 50 Ton Hydraulic Press

Welding Equipment Hobart 400 Amp Arc Welder (2) Linde 300 Amp TIG Welders Cobramatic 300A MIG Welder Gas Cutting & Welding Outfit Cajon Orbital Arc Welder Argon Enclosure for Nb & Ti Welding

Inspection Equipment Mitutoyo BRT-M507 Coordinate

Measuring Machine – 20” x 28” x 16” Optical comparator

Metrology Equipment (3) Brunson Optical Transit Squares (2) Wild Precision Optical Levels (2) Wild T-2 Theodolites (2) Taylor-Hobson Line Scopes (2) Talyvel Electronic Levels (3) Alignment Lasers Scope Stands, Scales, Targets, etc

Chemical Treatment For pre-weld BCP of Nb components Millipore 35 lph Ultra-pure Water

System w/ 350 liter storage Negative pressure room with 1200 CFM

fume hood Class 10 laminar flow bench for drying

and bagging

.

VF-8VF-5

SL-40

CMM

~ 60% of main facility devoted to manufacturing ops. (8000 sq.ft.)

Vacuum Test Equipment Varian Model 979 Mass

Spectrometer Leak Detector with 1x10-11 Sensitivity

Veeco Model MS-20T Mass Spectrometer Leak Detector with 1x10-9 Sensitivity

Turbomolecular pumping station

Chemistry

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 4 of 17

SRF Design, Analysis, and Prototyping at AES

RF TEST LAB

TECH LAB

NC MACHINESHOP

CHEM LAB

QC LAB

MACHINESHOP

EB WELDER(Early 2006)

OFFICES

OFFICES

SHIPPING &RECEIVING

WELDSHOP

OFFICES

RF TEST(FUTURE)LAB

AES Facility Medford, NY

N

Sept 1998 – 7,800 ft2

Nov 2003 – 11,500 ft2

Summer 2005 (Plan) – 17,000 ft2

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 5 of 17

SRF Design, Analysis, and Prototyping at AESAt AES Design Development is Continuous Iterative Process

Focus is to reach a mode of integration between disciplines that enables a seemless and constant exchange between physics and engineering– RF Layout

– Design Engineering

– Overall System Engineering

Initial AES activites in heavy ions stemmed from interactions with ANL staff on proton machines like APT and ATW.– Manufacturing planning and detailed costing.

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 6 of 17

SRF Design, Analysis, and Prototyping at AESHeavy Ion SRF Prototyping at AES

Prototyping work for RIA/ATLAS has been ongoing at AES since 2000 Prototyping is more than fabricating “first-of-a-kind” hardware. It is a

process of design development, engineering analysis, manufacturing producibility analysis, and fabrication resulting in a robust Program Plan, Schedule, and Cost Estimate

Collaborating with ANL, AES worked to develop fabrication approaches for the different classes of cavities

– Develop assembly sequence and detail part definition

– Develop manufacturing flow plans and schedules

– Develop cost estimates and facilities requirements

Five Cavities of four different types were then Prototyped– Quarter Wave Resonator

– Half Wave Resonator

– Double Spoke Resonator

– Two Triple Spoke Resonators at =.50 and =.62

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 7 of 17

SRF Design, Analysis, and Prototyping at AESThe Prototyping Process at AES

Cavity Prototyping – General Flow– From ANL/AES Manufacturing studies detailed designs were developed at ANL

– Designs (RF Definition with mechanical layouts) transferred to AES

– AES performed the forming work and most machining of the niobium parts

– Welding done by ANL at Sciaky in Chicago

– Final Integration and Test at ANL For the First Cavity, the Double Spoke Resonator, AES worked from AutoCAD

layouts done at ANL For the Final Cavities, the two Triple Spoke Resonators, AES imported Solid Models

coming directly out of ANL’s Microwave Studio and Pro/ENGINEER– Parts were fabricated with complex shapes that could not be “dimensioned” in the

traditional sense of an engineering drawing

– Paperless manufacturing The QWR and HWR used a mixed technique in the transition Engineering Analysis of the cavities also matured during this sequence

– Concurrent Design and Analysis were utilizing the same models for rapid design evaluation during Prototype fabrication

– The Triple Spoke stiffener scheme was developed concurrently with fabrication

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 8 of 17

SRF Design, Analysis, and Prototyping at AES

The Triple Spoke Example – Design, Analysis, Fabrication Flow

STEP File Solid Model of RF Space ANL – MWS Model

“Skin” the Model (ANL & AES in Pro/E)

Resulting Pro/E Assembly with Detail Parts

Design &

Manufacturing

EngineeringAnalysis

ANSYS Model of Structure (w/ He Vessel) and RF Space

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 9 of 17

SRF Design, Analysis, and Prototyping at AES

Analysis Example - Triple Spoke Model Stiffener Analysis

Design issue: Spoke resonators exhibit frequency shift due to variations in helium pressure

Analysis performed under the guidance of K. Shepard to attempt to null out that effect

In ANSYS, a structural model of the cavity/helium vessel structure and an RF model of the resonator “RF Space” were built. These models share common surfaces at the interface and deformations from the structural analysis are mapped onto the RF model where the f is calculated

A stiffener geometry was developed that reversed the sign of the f and allowed fine tuning by machining the stiffeners after fabrication

A second series of analyses is shown that examines the effect of a fast piezoelectric tuner

Performance was verified during cavity testing

16 radial stiffeners

1.25 “

14.7 psi in helium space

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 10 of 17

SRF Design, Analysis, and Prototyping at AES

Stiffener Analysis Result – Tune by Machining f with no stiffeners = +12.04 kHz 16 Radial Stiffeners added

– f = -6.64 kHz with full stiffeners (right)

– f = +3.92 kHz with machined stiffeners (left)

– Total tuning range of +10.56 kHz

Radial Displacements inches

Load = 14.7 psi in helium spaceProperties evaluated at RT

Radial Displacements inches

Cavity with Full Stiffeners.075 in.

.50 in.

Cavity with Machined Stiffeners

R .12 in.

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 11 of 17

SRF Design, Analysis, and Prototyping at AESFast Tuner Study

Analysis to determine the effect of 20 m actuation of piezoelectric tuner Analysis Result f = +120 Hz Verified in Cavity Test

Radial Displacements inches

Cavity

Properties evaluated at RT

20 micron actuation results in 14.9 lbs of load in the actuator

Radial Displacements inches

Helium vessel

Distribution of Radial Displacements (in.)

Cavity side -.42816 e-3Helium vessel side .35924 e-3

Tuner Location – Chosen by ANL to Maximize Tuner Effect

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 12 of 17

SRF Design, Analysis, and Prototyping at AESThe Fabrication Flow - Develop Detail Parts

Full Pro/E AssemblyANL

Center SpokeAssembly

Exploded View of Detail Parts for Fabrication

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 13 of 17

SRF Design, Analysis, and Prototyping at AES

Multi-Piece Multifunction Tools Directly from MWS Geometry

Geometry Direct from MWS Into Pro/E Tooling Models and Direct to NC Machines (STEP & IGES) Spoke Half Forming/Machining Tools

Beam Tube Saddle Forming/Machining Tool

Spoke Saddle Forming/Machining Tool

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 14 of 17

SRF Design, Analysis, and Prototyping at AES

ANL RIA Triple Spoke Fabrication at AES – Spokes & Tank

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 15 of 17

SRF Design, Analysis, and Prototyping at AESANL RIA Triple Spoke Fab. at AES – End Walls & Assembly M/C

End Wall Forming Tools

As-Formed End Walls Ready for Beam Tube Weld

Trim Cavity Ends Prior to TuningReady for Tuning

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 16 of 17

SRF Design, Analysis, and Prototyping at AES

ANL RIA =.50 Triple Spoke Tuning at AES

Tspoke2 Field (Sqrt(freq)%)

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 Tspoke9 Field (Sqrt(freq)%)

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

1st Bead Pull

4th (Final) Bead Pull

f0 = 345.909 MHz

f0 = 344.800 MHz

Target Frequency

f0 = 344.790 MHz

Field Balance

+/- 5%

Performing Bead Pull

In Bead Pull Fixture

Machining End Wall Flange for Tuning

T. Myers for J. Rathke - May 24, 2005 - HPSL Workshop - Slide # 17 of 17

SRF Design, Analysis, and Prototyping at AESSummary & Conclusions

ANL / AES have collaborated to produce five first-of-a-kind prototype cavities for RIA / ATLAS

This collaboration spanned the full design development horizon from Project Planning & Cost Estimating through Manufacturing & Producibility through Design & Analysis and finally through Fabrication

Under the leadership of ANL, the collaboration utilized the strengths of all organizations in a well integrated, concurrent development environment

The Triple Spoke example highlighted here is a blueprint for collaborations of this type in the future