1 Assembly and installation of TM0 in the Lab Assembly and installation of TM0 in the Lab F. Rossi September 19th, 2011 2 Assembly and installation of TM0 in the Lab TABLE OF CONTENTS 1. PETS Introduction Quality controls (fiducialisation and alignment) Time schedule 2. AS Introduction Quality controls (fiducialisation and alignment) Time schedule 3. TM0 Time schedule 3 Assembly and installation of TM0 in the Lab TABLE OF CONTENTS 1. PETS Introduction Quality controls (fiducialisation and alignment) Time schedule 2. AS Introduction Quality controls (fiducialisation and alignment) Time schedule 3. TM0 Time schedule 4 Assembly and installation of TM0 in the Lab PETS: introduction Vacuum flange with adapter Damped bars Tank (short) Coupler middle mm mm 202 mm Coupler extremity Frictional contact Frictional contact EBW Tank 5 Assembly and installation of TM0 in the Lab PETS: introduction (1) MACHINING & DELIVERY (1) MACHINING & DELIVERY (3) CLEANING Degreasing + deoxidation + passivation (3) CLEANING Degreasing + deoxidation + passivation (8) TIG WELDING 1.Fixed UHV flange + tube + minitank tube (short)Fixed UHV flange + tube + minitank tube (short) 2.Fixed UHV flange + tube + minitank tubeFixed UHV flange + tube + minitank tube (8) TIG WELDING 1.Fixed UHV flange + tube + minitank tube (short)Fixed UHV flange + tube + minitank tube (short) 2.Fixed UHV flange + tube + minitank tubeFixed UHV flange + tube + minitank tube (5) MACHINING 1.Coupler with on-off (x2)Coupler with on-off (x2) (5) MACHINING 1.Coupler with on-off (x2)Coupler with on-off (x2) (9) ARGON BRAZING (Au/Cu 35/65, 1020 C) 1.Coupler extremityCoupler extremity 2.Coupler middleCoupler middle (9) ARGON BRAZING (Au/Cu 35/65, 1020 C) 1.Coupler extremityCoupler extremity 2.Coupler middleCoupler middle (11) EBW 1.PETS unitPETS unit (11) EBW 1.PETS unitPETS unit (13) CONDITIONING (13) CONDITIONING (12) QUALITY CONTROL 1.Vacuum testVacuum test 2.Dimensional control on CMMDimensional control on CMM (12) QUALITY CONTROL 1.Vacuum testVacuum test 2.Dimensional control on CMMDimensional control on CMM (4) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.2 minitank rings + minitank tube (short)2 minitank rings + minitank tube (short) 2.2 minitank rings + minitank tube2 minitank rings + minitank tube 3.Chamber for on-off mechanism (x2)Chamber for on-off mechanism (x2) 4.Coupler with on-off half 1 + half 2 (x2)Coupler with on-off half 1 + half 2 (x2) 5.Adapter disk 3 + DN rotat. flange (insert )Adapter disk 3 + DN rotat. flange (insert ) (4) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.2 minitank rings + minitank tube (short)2 minitank rings + minitank tube (short) 2.2 minitank rings + minitank tube2 minitank rings + minitank tube 3.Chamber for on-off mechanism (x2)Chamber for on-off mechanism (x2) 4.Coupler with on-off half 1 + half 2 (x2)Coupler with on-off half 1 + half 2 (x2) 5.Adapter disk 3 + DN rotat. flange (insert )Adapter disk 3 + DN rotat. flange (insert ) (2) QUALITY CONTROL 1.Inlet inspectionInlet inspection 2.Dimensional controlDimensional control (2) QUALITY CONTROL 1.Inlet inspectionInlet inspection 2.Dimensional controlDimensional control (10) QUALITY CONTROL 1.Vacuum testVacuum test 2.Cooling circuit testCooling circuit test 3.FiducialisationFiducialisation (10) QUALITY CONTROL 1.Vacuum testVacuum test 2.Cooling circuit testCooling circuit test 3.FiducialisationFiducialisation (7) CLEANING 1.Coupler with on-off (x2)Coupler with on-off (x2) (7) CLEANING 1.Coupler with on-off (x2)Coupler with on-off (x2) (6) QUALITY CONTROL 1.Cooling circuit testCooling circuit test (6) QUALITY CONTROL 1.Cooling circuit testCooling circuit test 6 Assembly and installation of TM0 in the Lab PETS: introduction 4. Ar brazing (AuCu 25/75, 1040 C) 4. Ar brazing (AuCu 25/75, 1040 C) 9. Ar brazing (AuCu 35/65, 1020 C) 9. Ar brazing (AuCu 35/65, 1020 C) 11. EBW 5. Machining Coupler with on-off Chamber for on- off mechanism Minitank (short) Minitank Vacuum flange with adapter Coupler (middle) Coupler (extremity) 8. TIG welding 7. Cleaning 10. QC 12. QC 2. QC Dimensional control (Olivetti) 2. QC Dimensional control (Olivetti) Octant 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 1.Vacuum test 2.Dimensional control (Leitz) 1.Vacuum test 2.Dimensional control (Leitz) 1.Vacuum test 2.Fiducialisation 1.Vacuum test 2.Fiducialisation 6. QC 1.Cooling circuit test 7 Assembly and installation of TM0 in the Lab PETS: quality control Electron-Beam Welding (EBW) is a high-energy density fusion process that is accomplished by bombarding the joint to be welded with an intense (strongly focused) beam of electrons. The instantaneous conversion of the kinetic energy of these electrons into thermal energy as they impact and penetrate into the workpiece on which they are impinging causes the weld-seam interface surfaces to melt and produces the weld-joint coalescence desired. Welding Bearing Chuck driven by the welding machine Fixed V-support Ground 11. EBW 8 Assembly and installation of TM0 in the Lab PETS: quality control Bearing Upper eye-bolt Upper bolt Upper cap cover Lateral eye-bolt Holding- device Lower cap cover Lower bolt Lateral eye-bolt Nut Threaded rod Nut Bearing: allow EBW tooling rotation around its axis, once it is positioned on the EBW machine. Upper cap cover: apply clamping force to PETS unit, once the nut is screwed on the threaded rod. Upper bolt: fix upper cap cover and coupler (extremity). Eye-bolts: for lifting and handling. Threaded rod (M16): connection between the upper and the lower cap cover. Lower cap cover: sustain PETS unit during the assembly on the tooling. Lower bolt: fix lower cap cover and vacuum flange with adapter. Nut (M16): after it is screwed using a torque spanner, a compressive axial load is applied to PETS units (while the rod has tensile stresses). Holding device: fix axial and angular position of tanks. 11. EBW: tooling 9 Assembly and installation of TM0 in the Lab PETS: quality control 35 m 140 m 11. EBW: assembly on tooling 10 Assembly and installation of TM0 in the Lab PETS: quality control I. Fiducials Leitz PMM-C Infinity Dimensions: 1200x1000x700 mm Accuracy: 0.3+L/1000 m II. Fiducialisation III. Alignment 10. QUALITY CONTROL: fiducialisation 11 Assembly and installation of TM0 in the Lab PETS: introduction 4. Ar brazing (AuCu 25/75, 1040 C) 4. Ar brazing (AuCu 25/75, 1040 C) 9. Ar brazing (AuCu 35/65, 1020 C) 9. Ar brazing (AuCu 35/65, 1020 C) 11. EBW 5. Machining Coupler with on-off Chamber for on- off mechanism Minitank (short) Minitank Vacuum flange with adapter Coupler (middle) Coupler (extremity) 8. TIG welding 7. Cleaning 10. QC 12. QC 2. QC Dimensional control (Olivetti) 2. QC Dimensional control (Olivetti) Octant 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 1.Vacuum test 2.Dimensional control (Leitz) 1.Vacuum test 2.Dimensional control (Leitz) 1.Vacuum test 2.Fiducialisation 1.Vacuum test 2.Fiducialisation 6. QC 1.Cooling circuit test 12 Assembly and installation of TM0 in the Lab PETS: time schedule 13 Assembly and installation of TM0 in the Lab TABLE OF CONTENTS 1. PETS Introduction Quality controls (fiducialisation and alignment) Time schedule 2. AS Introduction Quality controls (fiducialisation and alignment) Time schedule 3. TM0 Time schedule 14 Assembly and installation of TM0 in the Lab AS: introduction Manifold cover with vacuum flange STACK (4 accelerating structures) Disks stack Manifold small cover WG damping interface WFM Manifolds 15 Assembly and installation of TM0 in the Lab (1) MACHINING & DELIVERY (1) MACHINING & DELIVERY (2) QUALITY CONTROL 1.Inlet inspectionInlet inspection (2) QUALITY CONTROL 1.Inlet inspectionInlet inspection (3) CLEANING Degreasing+deoxidation+passivation (3) CLEANING Degreasing+deoxidation+passivation (4) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.WFM WG cover + WFM WG body (x32=4x8)WFM WG cover + WFM WG body (x32=4x8) 2.Waveguide damping interface half 1 + half 2 (x32=4x8)Waveguide damping interface half 1 + half 2 (x32=4x8) 3.Stack type 1 (x6)Stack type 1 (x6) 4.Stack type 2 (x1)Stack type 2 (x1) 5.Stack type 3 (x1)Stack type 3 (x1) 6.Manifold cover (tank int.) + vacuum tube P1 (x8)Manifold cover (tank int.) + vacuum tube P1 (x8) 7.Manifold small cover 3 + small cover 3 insert (x32=4x8)Manifold small cover 3 + small cover 3 insert (x32=4x8) (4) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.WFM WG cover + WFM WG body (x32=4x8)WFM WG cover + WFM WG body (x32=4x8) 2.Waveguide damping interface half 1 + half 2 (x32=4x8)Waveguide damping interface half 1 + half 2 (x32=4x8) 3.Stack type 1 (x6)Stack type 1 (x6) 4.Stack type 2 (x1)Stack type 2 (x1) 5.Stack type 3 (x1)Stack type 3 (x1) 6.Manifold cover (tank int.) + vacuum tube P1 (x8)Manifold cover (tank int.) + vacuum tube P1 (x8) 7.Manifold small cover 3 + small cover 3 insert (x32=4x8)Manifold small cover 3 + small cover 3 insert (x32=4x8) (5) QUALITY CONTROL 1.Cooling circuit test (disks stacks)Cooling circuit test (disks stacks) (5) QUALITY CONTROL 1.Cooling circuit test (disks stacks)Cooling circuit test (disks stacks) (6) MACHINING 1.WFM WG brazed (x32=4x8)WFM WG brazed (x32=4x8) 2.WG damping interface (x32=4x8)WG damping interface (x32=4x8) (6) MACHINING 1.WFM WG brazed (x32=4x8)WFM WG brazed (x32=4x8) 2.WG damping interface (x32=4x8)WG damping interface (x32=4x8) (8) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.Manifold (hor) assembly (x8=1x8)Manifold (hor) assembly (x8=1x8) 2.Hor. manifold (mirrored) assembly (x8=1x8)Hor. manifold (mirrored) assembly (x8=1x8) 3.Vert. manifold assembly (x16=8x2)Vert. manifold assembly (x16=8x2) (8) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.Manifold (hor) assembly (x8=1x8)Manifold (hor) assembly (x8=1x8) 2.Hor. manifold (mirrored) assembly (x8=1x8)Hor. manifold (mirrored) assembly (x8=1x8) 3.Vert. manifold assembly (x16=8x2)Vert. manifold assembly (x16=8x2) (9) QUALITY CONTROL 1.Vacuum test (manifolds)Vacuum test (manifolds) (9) QUALITY CONTROL 1.Vacuum test (manifolds)Vacuum test (manifolds) (10) ARGON BRAZING (Au/Cu 35/65, 1020 C) 1.Structure type 1 (x6)Structure type 1 (x6) 2.Structure type 2 (x1)Structure type 2 (x1) 3.Structure type 3 (x1)Structure type 3 (x1) (10) ARGON BRAZING (Au/Cu 35/65, 1020 C) 1.Structure type 1 (x6)Structure type 1 (x6) 2.Structure type 2 (x1)Structure type 2 (x1) 3.Structure type 3 (x1)Structure type 3 (x1) (11) QUALITY CONTROL 1.Vacuum testVacuum test 2.Cooling circuit testCooling circuit test 3.FiducialisationFiducialisation (11) QUALITY CONTROL 1.Vacuum testVacuum test 2.Cooling circuit testCooling circuit test 3.FiducialisationFiducialisation (12) ARGON BRAZING (Au/Cu 50/50, 980 C) 1.Brazed stack 1Brazed stack 1 2.Brazed stack 2Brazed stack 2 (12) ARGON BRAZING (Au/Cu 50/50, 980 C) 1.Brazed stack 1Brazed stack 1 2.Brazed stack 2Brazed stack 2 (13) EBW 1.Stack 1Stack 1 2.Stack 2Stack 2 (13) EBW 1.Stack 1Stack 1 2.Stack 2Stack 2 (15) EBW 1.MB assemblyMB assembly (15) EBW 1.MB assemblyMB assembly (17) CONDITIONING (17) CONDITIONING (14) QUALITY CONTROL 1.Vacuum testVacuum test 2.Dimensional controlDimensional control (14) QUALITY CONTROL 1.Vacuum testVacuum test 2.Dimensional controlDimensional control (16) QUALITY CONTROL 1.Vacuum testVacuum test (16) QUALITY CONTROL 1.Vacuum testVacuum test AS: introduction x32 x8 x6x1 x8 x16 x6 x1 (7) CLEANING 1.WFM WG brazed (x32=4x8)WFM WG brazed (x32=4x8) 2.WG damping interface (x32=4x8)WG damping interface (x32=4x8) (7) CLEANING 1.WFM WG brazed (x32=4x8)WFM WG brazed (x32=4x8) 2.WG damping interface (x32=4x8)WG damping interface (x32=4x8) x32 16 Assembly and installation of TM0 in the Lab AS: introduction 4. Ar brazing (AuCu 25/75, 1040 C) 4. Ar brazing (AuCu 25/75, 1040 C) 6. Cleaning 8. Ar brazing (AuCu 25/75, 1040 C) 8. Ar brazing (AuCu 25/75, 1040 C) 10. Ar brazing (AuCu 35/65, 1020 C) 10. Ar brazing (AuCu 35/65, 1020 C) Stack type 1 Stack type 2 Structure type 1 Structure type 2 5. Machining 7. QC - Cooling circuit test 7. QC - Cooling circuit test 7. QC - Cooling circuit test 7. QC - Cooling circuit test 7. QC - Cooling circuit test 7. QC - Cooling circuit test 7. QC - Cooling circuit test 7. QC - Cooling circuit test 9. QC 1.Vacuum test 11. QC 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 17 Assembly and installation of TM0 in the Lab AS: introduction 4. Ar brazing (AuCu 25/75, 1040 C) 4. Ar brazing (AuCu 25/75, 1040 C) 6. Cleaning 8. Ar brazing (AuCu 25/75, 1040 C) 8. Ar brazing (AuCu 25/75, 1040 C) 10. Ar brazing (AuCu 35/65, 1020 C) 10. Ar brazing (AuCu 35/65, 1020 C) Stack type 1 Stack type 3 Structure type 1 Structure type 3 5. Machining 7. QC - Cooling circuit test 7. QC - Cooling circuit test 7. QC - Cooling circuit test 7. QC - Cooling circuit test 7. QC - Cooling circuit test 7. QC - Cooling circuit test 7. QC - Cooling circuit test 7. QC - Cooling circuit test 9. QC 1.Vacuum test 11. QC 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation (Leitz) 18 Assembly and installation of TM0 in the Lab AS: introduction 4 16 Structure type 1 Structure type Ar brazing (AuCu 50/50, 980 C) 12. Ar brazing (AuCu 50/50, 980 C) 14. QC 1.Vacuum test 2.Dimensional control (Leitz) 1.Vacuum test 2.Dimensional control (Leitz) 13. EBW 15. EBW 16. QC 1.Vacuum test 4 16 Structure type 1 Structure type 3 1.Vacuum test 2.Dimensional control (Leitz) 1.Vacuum test 2.Dimensional control (Leitz) 19 Assembly and installation of TM0 in the Lab AS: quality control Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic WEIGHT a. Intermediate piece 2 b. Brazed stack 1c. Brazed stack 1 and alignment check d. Brazed stack 1 and alignment check e. Brazed stack 2 and alignment check f. MB interconnection bellow + flange and final alignment check g. Weight DOF to be adjusted 12. Ar BRAZING (Au/Cu 50/50, 980 C) 20 Assembly and installation of TM0 in the Lab AS: quality control 11. QUALITY CONTROL: fiducialisation Conical bores Leitz PMM-C Infinity Dimensions: 1200x1000x700 mm Accuracy: 0.3+L/1000 m 21 Assembly and installation of TM0 in the Lab AS: quality control 1 st structure2 nd structure and measurement Auxiliary frameAlignment3 rd structure 4 th structure 12. Ar BRAZING (Au/Cu 50/50, 980 C) 22 Assembly and installation of TM0 in the Lab AS: introduction 4 16 Structure type 1 Structure type Ar brazing (AuCu 50/50, 980 C) 12. Ar brazing (AuCu 50/50, 980 C) 14. QC 1.Vacuum test 2.Dimensional control (Leitz) 1.Vacuum test 2.Dimensional control (Leitz) 13. EBW 15. EBW 16. QC 1.Vacuum test 4 16 Structure type 1 Structure type 3 1.Vacuum test 2.Dimensional control (Leitz) 1.Vacuum test 2.Dimensional control (Leitz) 23 Assembly and installation of TM0 in the Lab AS: time schedule 24 Assembly and installation of TM0 in the Lab TABLE OF CONTENTS 1. PETS Introduction Quality controls (fiducialisation and alignment) Time schedule 2. AS Introduction Quality controls (fiducialisation and alignment) Time schedule 3. TM0 Time schedule 25 Assembly and installation of TM0 in the Lab TM0: time schedule