may 9, 2012d. r. dietderich, larp cm-18 cable fabrication plans and experience d.r. dietderich...

May 9, 2012 D. R. Dietderich, LARP CM-18

Cable Fabrication Plans and Experience

D.R. DietderichLawrence Berkeley National Laboratory

bnl - fnal- lbnl - slacUS LHC Accelerator Research Program


Outline of the Presentation

• Cable inventory for HQ/LHQ and plans

• Cable R&D – 140mm to 150mm bore– Cable fabrication of 217 stack

• R&D to reduce HQ cable dimensions– Wire diameters 0.778 mm and 0.80 mm

• Cored cable R&D


HQ/LHQ Cable Parameters & Processing

• Nominal Parameters– Annealed wire 185-190C for 4 hours– Wire diameter: 0.778 mm – Thickness: 1.375 mm – Width: 14.8 mm – Keystone Angle – 0.75 deg.

• Stainless steel core, biased towards thick edge– Tape composition - 316L stainless steel– 8 mm wide– 0.025 mm thick


HQ/LHQ Cable Status• Cable available for coil winding

– “Z” will denote a cable with a core. – 1020Z-D

• 1UL insulated– 1021Z – A1, A2, B (4 UL)

• 1 UL insulated braided on by NEW• Insulation layer thickness 0.104 mm

– Nearly the same thickness as prototype run with 0.103 mm. • Used in HQ coil 17• 3 UL insulated with sleeve from Rev. Comp.

– 1021Z-C – R&D 1UL NOT insulated, PL ~85 mm • 1024Z – 5 UL fabricated,

• 1 UL 1 insulated • 4 UL-HQ (400m) not insulated (Save for HQ for LHQ)• Ti doped • Used HQ coil 18

• 1025Z – 1 UL (300m) LHQ practice cable• Ready to insulate at NEW


Next LHQ/HQ Cable Run• May to August

– LHQ cable, fabricate 2 UL (May)• Standard HQ/LHQ cable with core

– HQ cable with RRP 217 stack, 1+ UL (June)• Standard HQ/LHQ cable with core

– MQXF Cable for140-150mm bore (July-August)

• R&D run to define cable parameters• 40 strands• Wire diameter ~0.85 mm


Cable for 140-150 mm Bore


Possible Cable Parameters for 140 mm

• If wire diameter is 0.85 mm the cable:

• Width: ~18.25 mm

• Thickness: ~1.50 mm

• Keystone angle: ~0.65 deg.


Cored Cable 1012 Used in HQ Coil 12

• HQ cable 1012 (old cable parameters)– 35 strands with diameter of 0.80 mm– 1.44 mm mid-thickness,

• Did not increase mid-thickness with core addition

– 15.1 mm wide– 0.75 deg. Keystone angle– 8 mm wide, 0.025 mm thick stainless steel core

• Biased to thick edge of cable

– Core biased toward thick edge of the cable

• No fabrication issue with the addition of a SS core• Addition of the core did not degrade the Ic

– Measurements show a reduction of ~3% which is typical for this cable without a core

Mandrel with slot for adding a core


Objective of Cable R&D• To use existing HQ tooling cable dimensions

needed to be reduced to:– Provide more space azimuthally (i.e. thinner cable)– Provide more radial space (i.e. narrower cable)

• Cable R&D targets dimensions: – Reduce HQ cable thickness by 65-100 microns

• To 1.375 mm - 1.340mm

– Width target is < 15mm (14.7mm -15mm) • Accommodates dimensional changes of cable during

reaction• Thicker insulation or more insulation between layers and

tooling

– Keystone angle un-changed at 0.75 deg.


HQ Cable Parameters of R&D Cables

Width vs. Thickness for cables 1014 and 1015

14.70

14.75

14.80

14.85

14.90

14.95

15.00

1.32 1.33 1.34 1.35 1.36 1.37 1.38 1.39 1.40 1.41 1.42

Thickness (mm)

Wid

th (

mm

)

1014

1015

1014- P2 1014- P1

1014- R51014- S

TQ LQ

New HQ cable

HQ Box

Zone with Too much damage


Critical Current Cable 1014 with 0.80 mm

Un-deformed Round Wire

ExtractedStrands


RRR 1014 – 0.80 mm wire

RRR of 1014

0

20

40

60

80

100

120

140

160

180

1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65

Cable mid-Thickness

RR

R

LBL 1014 RRR

BNL 1014 RRR Wide Rolls

BNL 1014 RRR Narrow Rolls



Critical Current Cable 1015 – 0.778 mm wire


Extracted strands

1st Production cable 1017


Cable 1015 Sections I & L

• No significant sub-element damage is observed in the wire cross-sectional images

1015-L

1015-I


Summary

• HQ and LHQ cabling process established• Target cable parameters for MQXF presented• The critical current variation can be due to:

– Sample handling while preparing for Jc testing?

– Or localized damage in some strands during cabling? – Suggests that a cable testing facility is needed for

accurate cable critical current measurements.

• A stainless steel core can be added to the standard HQ cable without significant loss of critical current


Extra slides


1 Pass Cable with Stainless Steel Core

Frequency, f, Hz

0.00 0.02 0.04 0.06 0.08 0.10

To

tal

per

-cy

cle

loss

, Qt,cal,

104 J

/m3

0

5

10

15

20

25

Cable 1 Cable 2 Cable 1A

FO

EO


LARP Cable Fabrication • 2 pass process was developed to reduce dimensional changes

of a cable during coil processing and reaction– A cable is fabricated oversize in thickness, annealed (200C for 2-4 hrs),

and re-rolling to final thickness.• Very important -- Cable is permitted to get wider during the second pass • The anneal reduces the residual stress in the cable and the cable shortens

by 0.20 – 0.25%.

• 1 pass process has been developed for adding stainless steel (SS) cores to cables– Strand is annealed (190C for 4 hrs) prior to cabling – Cable is made to final dimensions

• Due to the mechanical differences between the strand and the SS core a 2 pass process is not possible.

• However, other core materials such as S-glass tape or MgO paper tapre with a SS core


Cable R&D to Reduce Cable Size

• The next slide shows the thickness and width of several cable samples – Cable 1014

• 34 strands with a diameter of 0.80 mm– Cable 1015

• 35 strands with a diameter of 0.778 mm

• “Blue Box” denotes the target parameters needed to accommodate the cable dimensional changes in the present tooling.– Dash line are the deduced parameters from R&D on

TQ and LQ coils• “Red Circle” denotes the new HQ parameters

with the 0.778 mm diameter strand


R&D to Reduce HQ Cable Dimensions

• New cable parameters: – Mid-thickness 1.375 mm from 1.44 mm– Width 14.80 mm from 15.10 mm– Keystone angle 0.75 deg. Unchanged

• New cable designs will provide more space in tool for cable dimensional changes– Have made the first production cable 1017 with new parameters

• HQ coil 14 has been fabricated and is ready to test in a mirror.

– Have just made a cored cable with the new cable parameters with a strand diameter of 0.778mm.

• Coil winding with the cored cable was OK – However, popped strands were produced going around the pole

• They are pushed back into position as winding continues

– Planning to cut HQ coil 12 into sections for inspection.

may 9, 2012d. r. dietderich, larp cm-18 cable fabrication plans and experience d.r. dietderich...

Documents

pass cable

cabling cable

core hq cable

production cable

thinner cable

hq cable thickness

larp cable fabrication

standard hq cable