F. Bertinelli

HTS Dipole Insert Developments

Future accelerator magnets will need to reach a magnetic field in the 20 T range. Reaching such a magnetic field is a challenge only reachable using high temperature superconductor (HTS) material. The high current densities and stress levels needed to satisfy the design criterion of such magnets make YBaCuO superconductor the most appropriate candidate especially when produced using the IBAD route. The HFM EUCARD program is aimed at designing and manufacturing a dipole insert made of HTS material generating 6 T inside a Nb3Sn dipole of 13 T at 4.2 K. In the HTS insert, engineering current densities higher than 250 MA/m2 under 19 T are required to reach the performances. The stress level is consequently very high. The insert protection is also a critical issue as HTS shows low quench propagation velocity. The coupling with the Nb3Sn dipole makes the problem even more difficult. The magnetic and mechanical designs of the HTS insert will be presented as well as the technological developments underway to realize this compact dipole insert.

Production and Quality Assurance of Main Busbar Interconnection Splices During the LHC 2008–2009 Shutdown

The main busbar interconnection splices of the Large Hadron Collider are assembled by inductive soldering of the Rutherford type cables and the copper profiles of the stabilizer. Following the September 2008 incident, the assembly process and the quality assurance have been improved, with new measurement and diagnostics methods introduced. In the 2008-2009 shutdown the resistance both in the superconducting and in the normal conducting states have been the focus for improvements. The introduction of gamma radiography has allowed the visualization of voids between cable and stabilizer. It is now known that during the standard soldering heating cycle solder is lost from the busbar extremities adjacent to the splice profiles, leaving parts of the cable in poor contact with the stabilizer. A room temperature resistance measurement has been introduced as a simple, non-destructive test to measure the electrical continuity of the splice in its normal conducting state. An ultrasonic test has been performed systematically in order to verify if the vertical gaps between the splice profiles are filled with Sn96Ag4 solder. Visual inspections of the different splice components before and after interconnection have been reinforced. The additional information gained has allowed targeted improvements in the splice production process. Ad-hoc machining of splice components avoids macroscopic gaps, additional soldering foil and copper shims are used in critical areas in order to improve the cable to stabilizer contact.

Production of Low-Carbon Magnetic Steel for the LHC Superconducting Dipole and Quadrupole Magnets

In 1996 CERN negotiated a contract with Cockerill Sambre-ARCELOR Group for the supply of 50 000 tonnes of low-carbon steel for the LHC main magnets: this was the first contract to be placed for the project, and one of the single largest. In 2005-after nine years of work-the contract is being successfully completed. This paper describes the steel specifically developed, known as MAGNETIL, its manufacturing and quality control process, organization of production, logistics and contract follow-up. Extensive statistics have been collected relating to physical, mechanical and technological parameters. Specific attention is dedicated to magnetic measurements (coercivity and permeability) performed at both room and cryogenic temperatures, the equipment used and statistical results. Reference is also made to the resulting precision of the fine-blanked laminations used for the magnet yoke. The technology transfer from the particle accelerator domain to industry is ongoing, for example for the screening of high voltage cables buried in the ground

Nondestructive Testing and Quality Control of the LHC Main Interconnection Splices

The Large Hadron Collider (LHC) main interconnection splices consist of Rutherford-type cable splice and busbar stabilizer splices. Busbar stabilizer splices have been consolidated during the first long LHC shutdown by soldering additional Cu shunts. In view of the large number of quality controls (QCs) that were integrated in the splice consolidation process, efficient and unambiguous QC procedures needed to be developed. Direct-current electrical resistance measurements have been selected for the control of the busbar splices and the individual shunts. About 400 000 resistance measurements performed at room temperature before and after each consolidation step have been analyzed. The resistance of the consolidated splices is comparable with the resistance of continuous busbars without splice. Resistance changes during the consolidation process correspond to those calculated from the changes in Cu cross-sectional area.

Consolidation of the 13 kA Interconnects in the LHC for Operation at 7 TeV

The accident in the LHC in September 2008 occurred in an interconnection between two magnets of the 13 kA dipole circuit. Successive measurements of the resistance of other interconnects revealed other defective joints, even though the SC cables were properly connected. These defective joints are characterized by a poor bonding between the SC cable and the copper stabilizer in combination with an electrical discontinuity in the copper stabilizer. A quench at the 7-13 kA level in such a joint can lead to a fast and unprotected thermal run-away and hence opening of the circuit. It has therefore been decided to operate the LHC at a reduced and safe current of 6 kA corresponding to 3.5 TeV beam energy until all defective joints are repaired. A task force is reviewing the status of all electrical joints in the magnet circuits and preparing for the necessary repairs. The principle solution is to resolder the worst defective joints and, in addition, to apply an electrical shunt made of copper across all joints with sufficient cross-section to guarantee safe 12-13 kA operation at 7-7.5 TeV. In this paper the various actions that have lead to this solution are presented.

The Interconnections of the LHC Cryomagnets at CERN: Strategy Applied and First Results of the Industrialization Process

The final interconnections of the LHC superconducting magnets in the underground tunnel are performed by a contractor on a result-oriented basis. A consortium of firms was awarded the contract after competitive tendering based on a technical and commercial specification. The implementation of the specific technologies and tooling developed and qualified by CERN has required an important effort to transfer the know-how and implement the follow-up of the contractor. This paper summarizes the start-up phase and the difficulties encountered. The organization and management tools put in place during the ramping-up phase are presented. In addition to contractual adaptations of the workforce, several configuration changes to the workflows were necessary to reach production rates compatible with the overall schedule and with the different constraints: availability of magnets, co-activities with magnets transport and alignment, handling of non-conformities, etc. Also the QA procedures underwent many changes to reach the high level of quality mandatory to ensure the LHC performance. The specificities of this worksite are underlined and first figures of merit of the learning process are presented.

Production of Austenitic Steel for the LHC Superconducting Dipole Magnets

The austenitic-steel collars are an important component of the LHC dipole magnets, operating at cryogenic temperature under high mechanical stress. The required steel, known as YUS 130S, has been specifically developed for this application by Nippon Steel Corporation (NSC), who was awarded a CERN contract in 1999 for the supply of 11 500 tonnes. In 2005-after six years of work-the contract is being successfully completed, with final production being ensured since October 2003 by Nippon Steel & Sumikin Stainless Steel Corporation (NSSC). The paper describes the steel properties, its manufacturing and quality control process, organization of production, logistics and contract follow-up. Extensive statistics have been collected relating to mechanical, physical and technological parameters. Specific attention is dedicated to measurements of magnetic permeability performed at cryogenic temperatures by CERN, the equipment used and statistical results. Reference is also made to the resulting precision of the fine-blanked collars

Development of a New Insulation Approach for the LHC Main 13 kA Interconnection Splices

In the long LHC (Large Hadron Collider) shutdown in 2013 it is foreseen to intervene on all the 13 kA interconnections in order to guarantee the necessary margin and redundancy to provide safe LHC operation at 7 TeV per beam. This implies reinforcement of the present interconnection configuration including a new insulation scheme of the busbars. The purpose of the new insulation model is to provide dielectric insulation with at least the same performance as its predecessor currently installed in the LHC machine, but in addition to contain the Lorentz forces. This paper describes the analytic and empirical approach of development to reach a new insulation concept based on state of the art materials and manufacturing techniques.

A Correlation Study Between Geometry of Collared Coils and Normal Quadrupole Multipole in the Main LHC Dipoles

The quality control implemented at all LHC dipole assemblers includes precise mechanical measurements of the geometry of collared coils. A cross-analysis performed between mechanical and magnetic measurements data shows a correlation between collared coils outer dimensions and the normal quadrupole multipole (b2) for one dipole assembler. The profile geometry of the single collars-as determined from 3D measurements at the collar suppliers and CERN-could not account alone for the significant left-right aperture asymmetry observed. This triggered a deeper investigation on different elements of the geometry of single collars. The results of this work show that the relative positioning of the collaring holes, allowing a small bending deformation of collars under the effect of coil pre-stress, is an important effect that generates a b2 multipole at the limit of specification. The study has deepened the understanding of the factors affecting collared coil geometry and field quality. The precision of 3D measurements at the collar suppliers and at CERN has been improved, and a tighter quality control has been introduced at the collar suppliers

Dependence of Magnetic Field Quality on Collar Supplier and Dimensions in the Main LHC Dipole

In order to keep the electro-magnetic forces and to minimize conductor movements, the superconducting coils of the main Large Hadron Collider dipoles are held in place by means of austenitic steel collars. Two suppliers provide the collars necessary for the whole LHC production, which has now reached more than 800 collared coils. In this paper we first assess if the different collar suppliers origin a noticeable difference in the magnetic field quality measured at room temperature. We then analyze the measurements of the collar dimensions carried out at the manufacturers, comparing them to the geometrical tolerances. Finally we use a magneto-static model to evaluate the expected spread in the field components induced by the actual collar dimensions. These spreads are compared to the magnetic measurements at room temperature over the magnet production in order to identify if the collars, rather than other components or assembly process, can account for the measured magnetic field effects. It has been found that in one over the three Cold Mass Assemblers the driving mechanism of the magnetic field harmonics b2 and a3 is the collar shape