J. Vlogaert

Test results on the long models and full scale prototypes of the second generation LHC arc dipoles

With the test of the first full scale prototype in June-July 1998, the R&D on the long superconducting dipoles based on the LHC design of 1993-95 has come to an end. This second generation of long magnets has a 56 mm coil aperture, is wound with 15 mm wide cable arranged in a 5 coil block layout. The series includes four 10 m long model dipoles, whose coils have been wound and collared in industry and the cold mass assembled and cryostated at CERN, as well as one 15 m long dipole prototype, manufactured totally in industry in the framework of a CERN-INFN collaboration for the LHC. After a brief description of particular features of the design and of the manufacturing, test results are reported and compared with the expectations. One magnet reached the record field for long model dipoles of 9.8 T but results have not been well reproducible from magnet to magnet. Guidelines for modifications that will appear in the next generation of long magnets, based on a six block coil design, are indicated in the conclusions.

Performance of the LHC final design full scale superconducting dipole prototypes

Within the LHC magnet program, a series of six, final design, full-scale superconducting dipole prototypes are presently being built in industry and tested at CERN. The main features of these magnets are: two-in-one structure, 56 mm aperture, six-block two layer coils wound from 15.1 mm wide graded NbTi cables, and all-polyimide insulation. This paper reviews the main test results of magnets tested at 4.2 K and 1.8 K. The results of the quench training, conductor performance, magnet protection, sensitivity to ramp rate and field quality are presented and discussed in terms of the design parameters and the aims of the full scale dipole prototype program.

Status report on the LHC main magnet production

The LHC ring will contain 1232 main dipole and 382 main quadrupole double aperture magnets. All main magnets are superconducting and employ Nb-Ti/Cu Rutherford type cables operated at 1.9 K. The dipole production has reached the equivalent of almost three octants of cold masses and nearly four octants of collared coils. The quadrupole production has reached 75 cold masses and over 150 bare magnets. The ramping up of large scale magnet production has posed several challenges which will be discussed, like: the coil size uniformity, coil pre-stress control, cold mass welding technique and the geometrical shape issues. The magnetic measurement results at warm will be presented together with their usage for the quality control in the production. The common features and differences of the three dipole producers will be discussed. The latest version of the production schedule will be presented.

Quench performance and field quality of the LHC preseries superconducting dipoles

The preseries production of the LHC main superconducting dipoles is presently being tested at CERN. The foremost features of these magnets are: twin structure, six block two layer coils wound from 15.1 mm wide graded NbTi cables, 56 mm aperture, polyimide insulation and stainless steel collars. The paper reviews the main test results of magnets tested to day in both normal and superfluid helium. The results of training performance, magnet protection, electrical integrity and the field quality are presented in terms of the specifications and expected performance of these magnets in the future accelerator.

Performance of the LHC final prototype and first pre-series superconducting dipole magnets

Within the LHC cryo-dipole program, six full-scale superconducting prototypes of final design were built in collaboration between Industry and CERN, followed by launching the manufacture of pre-series magnets. Five prototypes and the first of the pre-series magnets were tested at CERN. This paper reviews the main features and the performance of the cryo-dipoles tested at 4.2 K and 1.8 K. The results of the quench training, conductor performance, magnet protection, sensitivity to ramp rate and field characteristics are presented and discussed in terms of the design parameters.

Final prototypes, first pre-series units and steps towards series production of the LHC main dipoles

The LHC, a 7 TeV proton collider presently under construction at CERN, requires 1232, superconducting dipole magnets, featuring a nominal field of 8.33 T inside a cold bore tube of 50 mm inner diameter and a magnetic length of 14.3 in. This paper summarises the results of the program of the six LHC main dipole final prototypes and presents the performance measurements of the first magnets of the 90 pre-series units currently under manufacture by industry. Results of geometric and magnetic measurements are given and discussed. Finally, the major milestones towards the dipole magnets series manufacture are given and commented.

Description of the Main Features of the Series Production of the LHC Main Dipole Magnets

The series production of the LHC main dipole magnets was completed in November 2006. This paper presents the organization implemented at CERN and the milestones fixed to fulfill the technical requirements and to respect the master schedule of the machine installation. The CERN organization for the production follow-up, the quality assurance and the magnet testing, as well as the organization of the three main contractors will be described. A description of the design work and procurement of most of the specific heavy tooling and key components will be given with emphasis on the advantages and drawbacks.

Measurement and analysis of axial end forces in a full-length prototype of LHC main dipole magnets

A full-length, twin aperture prototype (MBP2N1) dipole magnet for the LHC project was assembled at CERN with collared coils delivered by industry. The design of this prototype is close to that foreseen for the dipole series manufacture as far the coil geometry and that of the yoke components are concerned. The bolts that transfer the axial magnetic forces from the coil ends to the cold mass end plates were instrumented to verify the axial coil support. These axial forces were initially measured after partial assembly, during a standard and an accelerated cool down introduction to 1.9 K, and during magnet excitation up to 9.2 T. High force levels were observed, triggering a comparison with analytical models and measurements routinely made on 1-m single aperture dipole models. The prototype magnet was re-assembled with lower initial axial force settings and with additional instrumentation, to monitor these forces during the entire assembly process, and re-tested, to possibly correlate axial forces with training behaviour. This paper reports about the experimental observation and provides models towards their understanding.

Status Report on the Series Production of the Main Superconducting Dipole Magnets for LHC

The LHC accelerator, at present under construction at CERN, Geneva, will make use of 1232 superconducting dipole magnets. The coils are wound with Rutherford type cable based on copper stabilized NbTi superconductors. The LHC machine will be operated at 1.9 K in superfluid helium. The unprecedented mass production of the superconducting dipole magnets, which involves three main contractors in Europe, is running steadily according to plan. This paper reports the outstanding technical issues encountered throughout the execution of the main manufacturing steps, which are the coil winding, curing and clamping in the collar structure, the 15-m long computer-controlled welding, the high-precision positioning operations for the cold mass finishing and the helium leak testing. The achieved production rates are discussed as well as the CERN plan for the completion of these important contracts

Electrical Integrity Tests During Production of the LHC Dipoles

For the LHC dipoles , mandatory electrical integrity tests are performed to qualify the cold mass (CM) at four production stages: individual pole, collared coil, CM before end cover welding and final CM. A description of the measurement equipment and its recent development are presented. After passing the demands set out in the specification, the results of the tests are transmitted to CERN where they are further analyzed. The paper presents the most important results of these measurements. We also report a review of the electrical nonconformities encountered e.g. inter-turn shorts and quench heater failure, their diagnostic and the cures