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Initial Activities for TESLA Cavity Development at RRCAT & BARC Jishnu Dwivedi & Avinash Initial Activities for TESLA Cavity Development at RRCAT & BARC Jishnu Dwivedi & Avinash Puntambekar TTC Meeting, New Delhi, India, Oct. 20– 23, 2008 Mar 8, 2008 DOE Budget Retreat

Outline • • • Oct 22, 2008 TESLA cavity Details of activities pursued Forming Outline • • • Oct 22, 2008 TESLA cavity Details of activities pursued Forming development EB welding activities Tuner activities Design capabilities TTC Meeting, New Delhi, India 2

TESLA Cavity Half Cells Equator Iris Nine cell TESLA cavity Beam Pipe End Flange TESLA Cavity Half Cells Equator Iris Nine cell TESLA cavity Beam Pipe End Flange Model of single cell cavity for nomenclature details Main aims for ILC • Frequency - 1. 3 GHz • E 0 > 35 MV/m ( Accelerating Electric field) • Q 0 = 1 x 1010 ( Quality factor) Oct 22, 2008 TTC Meeting, New Delhi, India 3

Our work plan • Generate know-how for SRF cavity manufacturing through prototype production • Our work plan • Generate know-how for SRF cavity manufacturing through prototype production • In-house forming & machining of half cells. • EB welding : two fold strategy – Use industrial infrastructure – Collaborate with other institute having expertise & infrastructure • Transfer the know-how to industry for series production. • Build long term partnership with industry for future large scale production for domestic programme as well as International collaborations • Plans for establishing manufacturing, tuning, processing and testing infrastructure Oct 22, 2008 TTC Meeting, New Delhi, India 4

Details of activities pursued • Forming development • Development of EB welding fixtures • Details of activities pursued • Forming development • Development of EB welding fixtures • Going through the forming, trimming, frequency measurement, welding, tuning cycle • First process qualification on dummy material (Al and OFE copper) on single cell cavity • Niobium forming at RRCAT • EB welding trials for Single cell cavity in Al initiated • Work on EB welding of niobium in close association with IUAC, New Delhi (for faster learning) • Work initiated on new tuner concept Oct 22, 2008 TTC Meeting, New Delhi, India 5

Work progress Activity Date Work on tooling started Sept 2007 EB welding fixture started Work progress Activity Date Work on tooling started Sept 2007 EB welding fixture started Jan 2008 First CC forming dies May 2008 (qualified on OFE copper) received at Fermilab Qualification on Nb started Sept 2008 First EB welding of Al half cells Sept 2008 First Al single cell EBW trial Oct 2008 Tuner design trials Oct 2008 Oct 22, 2008 TTC Meeting, New Delhi, India 6

Tooling development Machining of Dies Deep Drawing and coining of half cells Machining of Tooling development Machining of Dies Deep Drawing and coining of half cells Machining of half cells at equator and iris CMM inspection of half cell profile Analysis of formed geometry (profile errors) Yes Tooling Qualified Oct 22, 2008 Within ± 0. 2 mm No Tweaking of Tooling Profile TTC Meeting, New Delhi, India 7

Tooling development Qualified one complete set of forming tooling (Center, Long End & Short Tooling development Qualified one complete set of forming tooling (Center, Long End & Short End Cell) using OFE copper cell forming. Forming Tooling (Profile ± 30 microns) One center cell forming tooling received & inspected at Fermilab Formed Half Cells Oct 22, 2008 TTC Meeting, New Delhi, India 8

Deep drawing & coining About 40 Al, OFE copper half cells and one niobium Deep drawing & coining About 40 Al, OFE copper half cells and one niobium half cell formed. Deep Drawing Formed Half Cell Oct 22, 2008 Coining TTC Meeting, New Delhi, India 9

Machining • Developed Machining fixtures for EB weld features on equator & iris. • Machining • Developed Machining fixtures for EB weld features on equator & iris. • Several Al, OFE copper and one niobium half cell machined. Machining of Iris face Machining in progress Oct 22, 2008 Machined Half Cell TTC Meeting, New Delhi, India 10

Half cell inspection Result on OFE copper half cells Parameter Target Value Obtained Value Half cell inspection Result on OFE copper half cells Parameter Target Value Obtained Value Profile tolerance, mm ± 0. 2 Parallelism of equator and iris faces, mm 0. 02 0. 03 Roundness of equator ID, mm 0. 05 0. 03 0. 05 0. 01 (After machining) Roundness of iris OD, mm (After machining) Oct 22, 2008 TTC Meeting, New Delhi, India 11

Half cell inspection Result on Niobium half cells Parameter Target Value Obtained Value Profile Half cell inspection Result on Niobium half cells Parameter Target Value Obtained Value Profile tolerance, mm ± 0. 2 ± 0. 3 Parallelism of equator and iris faces, mm 0. 02 0. 12 Roundness of equator ID, mm 0. 05 0. 38 (As formed) 0. 05 (As formed) (After machining) Roundness of iris OD, mm (After machining) Oct 22, 2008 TTC Meeting, New Delhi, India 12

Half cell inspection Profile inspection of niobium half cell- (error magnified) Rolling direction - Half cell inspection Profile inspection of niobium half cell- (error magnified) Rolling direction - Magenta Transverse to rolling direction - Blue Anisotropy of niobium seems to be the origin of errors Oct 22, 2008 TTC Meeting, New Delhi, India 13

Electron beam welding • The next step in SC cavity manufacturing is joining “formed” Electron beam welding • The next step in SC cavity manufacturing is joining “formed” parts using EB welding • EB welding is a critical process in SC cavity manufacturing • One major reason limiting the high field gradient - EB welding defects – “spatter” or “pits” • Plan of EB Welding for Single cell Half cell – Parts Beam pipe • Long End Half Cells • Beam Pipe • End Flange End flange Oct 22, 2008 TTC Meeting, New Delhi, India 14

EB welding activities EB welding trial on Aluminum cavity M/s Laxmi technology & Engineering EB welding activities EB welding trial on Aluminum cavity M/s Laxmi technology & Engineering Industry Coimbtour EB welding fixtures for Single cell cavity – Developed and used in this attempt Inspection of Cylindricity Rolled & Welded beam pipes - Dedicated rolling machine developed - As rolled Cylindricity achieved 0. 4 mm - A dedicated turning fixture developed for pipe machining after long-seam welding to fit onto flange & half cell Oct 22, 2008 TTC Meeting, New Delhi, India 15

EB welding activities Beam pipe- end flange welding Setting inside the EBW chamber Oct EB welding activities Beam pipe- end flange welding Setting inside the EBW chamber Oct 22, 2008 TTC Meeting, New Delhi, India 16

EB welding activities Half-cell to beam-pipe welding Assembly for half cell- beam pipe flange EB welding activities Half-cell to beam-pipe welding Assembly for half cell- beam pipe flange subassembly Setting inside the EBW chamber Iris Welded Half cell assembly Steps before equator welding Mechanical Measurement Frequency Measurement Ready for Equator weld Oct 22, 2008 TTC Meeting, New Delhi, India Estimation of trimming length Trimming of equator length 17

EB welding activities Weld shrinkage measurement Half cell – Pipe Flange assembly height measurement EB welding activities Weld shrinkage measurement Half cell – Pipe Flange assembly height measurement for measurement of weld shrinkage Before After Weld welding Shrinkage mm mm mm 219. 49 218. 99 0. 5 Assly # 106 219. 71 218. 96 0. 75 219. 41 218. 53 0. 88 219. 67 218. 94 0. 73 218. 62 Assly # 117 218. 97 219. 03 218. 97 218. 25 218. 42 218. 64 218. 6 0. 37 0. 55 0. 39 0. 37 Measurement before & after welding to estimate the weld shrinkage 0. 37 to 0. 88 Assembly # 117 has more uniform shrinkage. Needs study & improvement Oct 22, 2008 TTC Meeting, New Delhi, India 18

First EB welding trial 1. 3 GHz Single cell Aluminum cavity Cleaned As received First EB welding trial 1. 3 GHz Single cell Aluminum cavity Cleaned As received Oct 22, 2008 TTC Meeting, New Delhi, India 19

EB welding activities Welding half cells to make dumbell Setting inside the EBW chamber EB welding activities Welding half cells to make dumbell Setting inside the EBW chamber Oct 22, 2008 TTC Meeting, New Delhi, India Welded dumbell 20

EB Welding fixture development A new “Slip Ring” Concept 9 cell TESLA Type cavity EB Welding fixture development A new “Slip Ring” Concept 9 cell TESLA Type cavity for ILC This fixture concept permits both inner & outer weld at Iris in single pump down significantly saving weld cycle time Better control of welding distortion 10 IRIS weld per nine cell cavity 8 Dumbell & 2 End Group to End cell Actual prototype fixture-June-08 Concept-Dec-07 Oct 22, 2008 Qualification in progress TTC Meeting, New Delhi, India 21

MOU-RRCAT & IUAC-Aug 2008 • Forming of Nb half cells initaited • Plans to MOU-RRCAT & IUAC-Aug 2008 • Forming of Nb half cells initaited • Plans to do welding on Niobium with IUAC • • Electron Beam Welding machine at IUAC : 15 k. W (60 k. V, 250 m. A) Chamber of size 2. 5 m × 1. 0 m, Oct 22, 2008 TTC Meeting, New Delhi, India 22

Scissors tuner A new mechanism for cavity tuning- Mundra, V. Jain, RRCAT Salient features Scissors tuner A new mechanism for cavity tuning- Mundra, V. Jain, RRCAT Salient features § Simple, easy to fabricate and low cost, § All flexures except the central pin joint §Two flanges on He vessel & two scissors, §Scissor levers are straight & identical, §PZT fast actuators integration possible, First steel prototype being tested at room temperature force and uniformity of deformation. S. S. Dry lub. Ball Screw Stepper motor, harmonic Drive Rectangular Flanges Helium Vessel Flexure Joints Scissors Levers Pin & Dry lub. S. S. bearing Work on tuner is also going on at BARC Oct 22, 2008 TTC Meeting, New Delhi, India 23

Design capabilities at RRCAT • Long experience of design and simulation of normalconducting RF Design capabilities at RRCAT • Long experience of design and simulation of normalconducting RF cavities, • Multiphysics simulation in electrodynamics, structural computational fluid dynamics, thermal, structural, dynamics and • Parametric design capability for coupled Electrodynamics and structural simulations in single environment • CAD-Simulation tools- I-DEAS, ANSYS, CST-MWS, SUPERFISH, Oct 22, 2008 TTC Meeting, New Delhi, India UG-NX, Auto. CAD, 24

Future plan on cavity activities • Continue with single cell prototypes in aluminum- leak Future plan on cavity activities • Continue with single cell prototypes in aluminum- leak test, frequency and field symmetry test • Tuning of this cavity • Forming, EB welding & tuning of Nb single cell cavity ( IUAC collaboration) • Continue work on tuner development and testing Oct 22, 2008 TTC Meeting, New Delhi, India 25

Summary • RRCAT has capability for design & manufacturing of normal conducting cavities, • Summary • RRCAT has capability for design & manufacturing of normal conducting cavities, • Now embarking on SC technology with TESLA cavity • Manufacturing progress in cavity forming & welding, • Design initiated for tuners • With inter-laboratory-industries collaboration we are developing required technology and man power training for coming projects, • Focus on Synergetic approach to benefit domestic programme & international collaboration. Thank you Oct 22, 2008 TTC Meeting, New Delhi, India 26