rossana bonomi, alberto degiovanni, marco garlasché, silvia verdú andrés, rolf wegner 3 ghz high...
TRANSCRIPT
Rossana Bonomi, Alberto Degiovanni, Marco Garlasché, Silvia Verdú Andrés,
Rolf Wegner
3 GHz high gradient test cavities
acknowledgmentsacknowledgments
Thank you• entire CLIC team• in particular Walter, Alexej, Germana, Erk, Igor,
Jan, Wilfridfor all advice, discussions and help for our project
Thank you• Jiaru and Walter
for scheduling our meeting today
2
19/04/23
2
aim of this meeting
to present the 3 GHz test cavity design
to get feedback, suggestions, recommendations=> production will start in ~ 2 weeks
discussion of open issues
3
19/04/23
3
outline
Motivations and Objectives of the 3 GHz high gradient test
– Rolf Wegner
Advantages of higher gradient for LIGHT – Alberto
Degiovanni
RF design of the test cavities – Silvia Verdú Andrés
Cooling of the test cavities – Rossana Bonomi
Mechanical design – Marco Garlasché
Tolerances and tuning – Rolf Wegner
Parameter list for high gradient test
Open issues / questions
4
19/04/23
4
19/04/23
4
Motivations and Objectives of the
3 GHz high gradient test
Rolf Wegner
19/04/23
5
Motivations
design values / break down limits @ 3 GHz LIBO (LInac BOoster for protontherapy):
design: Es= 1.8 Kilp. = 84 MV/m test: Es> 2.6 Kilp. = 122 MV/m G. Loew, J. Wang: (http://www.slac.stanford.edu/pubs/slacpubs/5250/slac-pub-5320.pdf)
19/04/23
6
Rolf Wegner
motivations of high gradient test
design values / break down limits @ 3 GHz
LIBO: Es> 2.6 Kilp. = 122 MV/m
G. Loew, J. Wang: Es> 300 MV/m = 6.4 Kilp.
modified Poynting vector + scaling laws from X and K-band:
for BDR= 10-6 1/m, Tpulse= 2.0 µs, Sc= 1.5 MW/mm2
=> Es> 300 MV/m = 6.4 Kilp.
Can a 3 GHz standing wave cavity be operated reliably with Es= 150 MV/m = 3.2 Kilp. ?
=> high gradient test 19/04/23
7
Rolf Wegner
objectives of high gradient test
1. operation limit for S-band cavities (BDR)2. applying found limit to future design
ensure reliable operation optimise efficiency by knowing limitations
3. BDR at S-band described by Es (Kilp.) or mod. Poynting vector + scaling law (X, K-band)
4. scaling law BDR ~ Es30 Tpulse
5 valid at S-band ?5. dependency of BDR on temperature, rep. rate6. assembly procedure
TERA: minimising machining cost CLIC: maximising gradient cost optimisation: machining, linac length, operating (power)
19/04/23
8
Rolf Wegner
Advantages of higher gradient for LIGHT
Alberto Degiovanni
19/04/23
9
LIGHT (IDRA-I)
Proton accelerator @ 3 GHzW = 30 230 MeV (β = 0.26 0.59)
20 acc. modules 1 unit = 2 modules 1 module = 2 tanks 1 tank = 16 ACs
Klystron TH2157: 7.5 MW peak powerES ≈ 90 MV/m (1.8 Kilp)
30 MeV cyclotron by IBA
R A D I O P H A R M A C Y
P R O T O N T H E R A P Y
≤230 MeV
30 MeV
70 MeV
Linac for Image Guided
Hadron Therapy = LIGHT
19 m
19/04/23
10
Alberto Degiovanni
LIGHT (IDRA-I)
With the current acc. gradient (17 MV/m) each modules consumes about 2.6 MW of peak power, but the klystrons can provide up to 5.4 MW (with 28% reduction for losses)
The accelerating gradient can be increased by 44 % (17 MV/m 24.5 MV/m)
ES increases, up to 130 MV/mThe total length decreases from 19 m to 15 m
44.1MW 6.2
MW 4.5''
0
0 P
P
E
E L
ZT
TEnP
2
20
19/04/23
11
Alberto Degiovanni
LIGHT (pediatric IDRA)
4.1 5.1 6.1 7.4 8.8 10.4 12.1 14.1 16.2 18.5 cm0.9 cm in water
19/04/23
12
Alberto Degiovanni
LIGHT (full IDRA)
~ 19 m
~ 15 m
19/04/23
13
Alberto Degiovanni
Advantages of IDRA-II
Reduce the number of modules, and so of modulators and of klystrons (17 13)
Reduce the length for ‘pediatric IDRA’ and ‘full IDRA’ (19 m 15 m)
Make good use of modulators and klystrons
…but Peak Power consumption increases by 33% (52 MW 70 MW)
19/04/23
14
Alberto Degiovanni
Optimization strategies
ZTT dependence on the ratio ES/E0 (with nose radius taken as a parameter)
gap 2mm
gap 11mm
With ES=160 MV/m
- - - E0= 25 MV/m
- - - E0= 35 MV/m
19/04/23
15
Alberto Degiovanni
RF design of the test cavities
Silvia Verdú Andrés
19/04/23
16
Introduction
Two structures with different slots* have been designed in order to test the breakdown rate:
Breakdowns can occur in the coupler region if the structure has a small slot.
The perturbation of the fields is high when the slot is too big.
[*] Slot: Aperture which links the cell with the waveguide
Waveguide WR284
Coupler
Aperture for adquisition
Cell
19/04/23
17
Silvia Verdú Andrés
Basic cell geometry optimization
Superfish was used to optimize the cell geometry.
The Outer Corner Radius RCO and Radius R are different for each test cavity.
Cell parameter Symbol Value
Length [mm] L 18.9
Gap length [mm] g 4.7
Inner Corner Radius [mm]
RCI1.9
Inner Nose Radius [mm]
RNI1
Outer Nose Radius [mm]
RNO1
Cone Angle [°] C25
Septum Thickness [mm]
S 3
Bore Radius [mm] RB3.5
RCO
RCI
R
L
S/2
RB RNI
RNO
C
19/04/23
18
Silvia Verdú Andrés
Tuning sensitivity
f vs. R
HFSS 3DSuperfis
h2D
Scaling factor* SF-HFSS
fSF/fHFSS, QSF/QHFSS
Process of design
Cavityf0SF=2998.5 GHz,
R0
Cavityf1HFSS, R0
StructureLS /
=1.5
Structuref2HFSS, R0
• Simulate two cavities with different Slot Length
• Exponential law
f2SF
∆f = f0SF-f2SF
Structuref0SF, f3HFSS,
R1
[*] fSF/fHFSS= 0.9992
n
b
a
b
a
x
x
x
x
19/04/23
19
Silvia Verdú Andrés 19/04/23
19
Silvia Verdú Andrés
Mesh
Max. element length for: Cavity + Coupler………3
mm
Max. surface deviation for: Cavity + Coupler.…0.02
mm
Max. delta frequency (convergency): 0.1 %
19/04/23
20
Silvia Verdú Andrés
~65 mm
19/04/23
20
Silvia Verdú Andrés
Max. element length for:• All………………….. 5 mm• Beam pipe……… 0.8 mm• Coupler…………. 1.2 mm
Max. surface deviation for All: 0.5 mm
Special Mesh
19/04/23
21
Silvia Verdú Andrés 19/04/23
21
Silvia Verdú Andrés
Max. element length for:• All………………….. 5 mm• Beam pipe……… 0.8 mm• Coupler…………. 1.2 mm
Max. surface deviation for All: 0.5 mm
Special Mesh
19/04/23
22
Silvia Verdú Andrés 19/04/23
22
Silvia Verdú Andrés
Coupling between the cell and the waveguide
Power
Short-cut
LSHORT
SW/2
SL
SD
19/04/23
23
Silvia Verdú Andrés
Test cavities
Cavity
Radius [mm] 32.61
Outer Corner Radius [mm]
3.4
Coupler
Length SL 28.8
Width SW 3
Depth SD 5
19/04/23
24
Silvia Verdú Andrés
Coupler
Length SL 25.5
Width SW 6
Depth SD 5
Cavity
Radius [mm] 32.38
Outer Corner Radius [mm]
2.0
Waveguide WR284
Height 72.14
Width 34.036
1st Test Cavity 2nd Test Cavity
19/04/23Silvia Verdú Andrés
Test Cavities
Frequency [GHz] 2.9985
fHFSS [MHz] 0…+3
Q0HFSS 8880
ZTT [MOhm/m] 67
df/dR -70 MHz/mm
Coupling coefficient
1.5 ±0.05
19/04/23
25
Silvia Verdú Andrés
Maximum fields
S
E
Field Cell Coupler
Emax [MV/m] 150 63
E0 [MV/m] 23 ----
SCmax [MW2/mm2] 0.46 0.15
P[kW] 140 3
19/04/23
26
Silvia Verdú Andrés
Purpose: evaluate maximum fields in cell and coupler. If fields are too big in the coupler region, breakdowns can be originated there.
Conclusions: No breakdowns expected in coupler.
done for the 1st Test Cavity
19/04/23
26
Silvia Verdú Andrés
27
Fields AsymmetriesE-field variation
19/04/23
27
Silvia Verdú Andrés
Mejorar fig.!
Conclusion: small perturbations of the fields
-0,04
-0,02
0
0,02
0,04
0 0,5 1 1,5 2 2,5
East Line [mm]
(E-N
)/N
-0,04
-0,02
0
0,02
0,04
0 0,5 1 1,5 2 2,5
West Line [mm]
(W-N
)/N
-0,04
-0,02
0
0,02
0,04
0 0,5 1 1,5 2 2,5
South Line [mm]
(S-N
)/NPurpose: the slot perturbes the fields.
We study the perturbation of the slot in the field pattern
done for the 2nd Test Cavity
W
S
N
E
19/04/23Silvia Verdú Andrés
Cooling of the test cavities
Rossana Bonomi
19/04/23
28
Geometry of OhMEGA129
cooling channel
coupling slot
tuner
flange
cooling plates
inlet-outlet coolant
19/04/23
29
Rossana Bonomi
Sizing channel (MatLab) 1/2
Requirements Average power to cool (350 W) Nº of parallel circuit (2) Turbulent flow (Re>104) Avoid erosion/corrosion (v < 2 m/s) Reference temp. for coolant
properties (37ºC) High heat transfer coefficient
(~104): minimization of the surface
30
19/04/23
30
Rossana Bonomi
2 4 6 8 10
x 10-3
0
1
2
3
4x 10
4
X: 0.0055Y: 1.39e+004
REYNOLD no circuits 2 ref temp 37
Deq [m]
Re
[]
dTio 1
dTio 2dTio 3
Sizing channel (MatLab) 2/231
Choices dT in-out = 1ºC Deq = 5.5 mm Re = 13900 v = 1.77 m/s h = 10020 W/m2/K
2 4 6 8 10
x 10-3
0
2
4
6
8x 10
4
X: 0.0055Y: 1.002e+004
CONV COEFF no circuits 2 ref temp 37
Deq [m]
h [
W/m
2/K
]
dTio 1
dTio 2dTio 3
2 4 6 8 10
x 10-3
0
5
10
15
X: 0.0055Y: 1.771
SPEED no circuits 2 ref temp 37
Deq [m]
v [
m/s
]
dTio 1
dTio 2dTio 3
19/04/23
31
Rossana Bonomi
Calculated Data
EACH CIRCUIT (2 parallel circuits)
Surface 4320 mm2
Mass flow 0.042 kg/s (~ 150 l/h = 2.5 l/min)
Expected temp difference wall-axis: ΔTw-a = (P/2)/(h*S) ~ 4.5ºC
32
19/04/23Rossana Bonomi
dT in-out = 1ºC Deq = 5.5 mm Re = 13900 v = 1.77 m/s h = 10020
W/m2/K
Geometry, Materials33
Symmetry of thestructure
OFE Copper C10100
316 Stainless Steel
19/04/23
33
Rossana Bonomi
Steady State Thermal – Boundary C. 1/2
34
Heat load distribution from Superfish
19/04/23
34
Rossana Bonomi
Steady State Thermal – Boundary C. 2/2
35
radiation + convection with
stagnant ambient air
Forced convection
inside channel19/04/23
35
Rossana Bonomi
Steady State Thermal – Results36
Coolant Reference Temperature 37ºC
Delta max temp: 15≤ ºC
19/04/23
36
Rossana Bonomi
Static Structural – Boundary C.37
Frictionless Support lower
face
Symmetry
Ambient and
vacuum pressure
19/04/23
37
Rossana Bonomi
Static Structural – Results38
Max deformation:
70 micron Left nose deformation:
3 micron
Right nose deformation:
-3 micron
19/04/23
38
Rossana Bonomi
Static Structural – Results39
All stresses less than 10
MPa
19/04/23
39
Rossana Bonomi
Expected Frequency Shift40
Deformations lead to frequency shift
19/04/23
40
Rossana Bonomi
Conclusions41
Cooling controls temperature (difference between nose and cooling plates less than 15°C)
Cooling keeps stresses far below the maximum yield stress for this material
19/04/23
41
Rossana Bonomi
Mechanical Design
Marco Garlasché
19/04/23
42
Assembly design
Model of accelerating system(half cells, tuning rod)
Coupling system(waveguide, Lil flanges)
Connection to acquisition(CF flanges)
Cooling system(two plates, in-out pipes)
19/04/23
43
Marco Garlasché
Model of accelerating system44
19/04/23
Two asymmetrical half cells: easier brazing, no spikes in slotCavities: machining precision of 0.02 mm.
# 1 # 2
Cavity radius [mm] 32.61 32.38
Inner corner radius [mm] 3.4 2.0
Coupling slot [mm] 28.8 x 3 25.5 x 6
19/04/23
44
Marco Garlasché
Acquisition angle
Acquisition angle: 90˚
CF flange mating surface carved 6mm deep for better acquisition (5.8˚ @ highest point )
19/04/23
45
Marco Garlasché
First half cell: brazing
OFE Copper
Brazing for connection with: 2nd half cell CF flange
One tuner on top, diametrical to coupling slot
78 mm
87 mm
19/04/23
46
Marco Garlasché
Second half cell
OFE Copper
Brazing for connection with CF flange
19/04/23
47
Marco Garlasché
Waveguide
Brazing with cell
Brazing with LIL flange
OFE Copper
Any experience on brazings directly on waveguide walls?
236 mm
34.036 mm
72.136 mm
19/04/23
48
Marco Garlasché
Cooling plates
OFE Copper / 316 LN
Two pipes coated and brazed to cooling plate
Usual dimension for coating ?
19/04/23
49
Marco Garlasché
Tolerances and Tuning
Rolf Wegner
19/04/23
50
tolerances
part dz dr df
µm µm kHz
1. top straight ± 20 ± 10 ± 1022
2. OUTER_CORNer_radius ± 20 ± 10 ± 1008
3. web ± 20 ± 10 ± 1065
4. INNER_CORNer_radius ± 20 ± 10 ± 182
5. nose angle ± 20 ± 10 ± 504
6. OUTER_NOSE_radius ± 20 ± 10 ± 3654
7. flat_top ± 20 ± 10 ± 240
8. INNER_NOSE_radius ± 20 ± 10 ± 2001
9. beampipe ± 20 ± 10 ± 32
total ± 9707
12
3
456
78
9
z
rfull cell dL=2dz= ± 40 µm
19/04/23
51
Rolf Wegner
tuner
tuning range: -1 .. +19 MHz
reduction in Q: 0 .. -5%
Ø tuner: 8.4 mm
19/04/23
52
Rolf Wegner
tuning
df [MHz]
compensation dR [mm]
sensitivity dR= + 1.0 mm - 70
sensitivity tuner dL= +1.0 mm + 3.0
machining tolerances ± 10 compensated by tuner
tuner (dL= 0 mm) - 9.0 + 0.129
thermal expansion (dT= 15 K) - 2.0 - 0.024
air => vacuum (T0=20°C) + 0.97
Tuning: f0(air, T0=20°C)= 2999.530 MHz
=> f0(vacuum, To=35°C)= 2998.500 MHz 19/04/23
53
Rolf Wegner 19/04/23
53
Parameter list for high gradient test
19/04/23
54
parameter list for high gradient test
1st cavity (slot width= 3.0 mm)
2nd cavity (slot width= 6.0 mm)
Q0, 2D 9110 8988
Q0, 3D 8884 8876
Qloaded,expected (tuner: 3%, T=35°C: 3%,
surf. roughness, assembly => total - 9%)
4042 4039
Es= 250 MV/m Pin= 380 kW Pin= 380 kW
Tpulse * frep 3 μs * 300 Hz 0.9 ‰
Pin,avg= 340 W Pin,avg= 340 W
19/04/23
55
parameter list for high gradient test
1st cavity (slot width= 3.0 mm)
2nd cavity (slot width= 6.0 mm)
Pin
[kW]Tpulse
[μs ]Es
[MV/m]Sc
[MW/mm2]
lg(BDR)!
X+K !
Es [MV/m]
Sc [MW/mm2]
lg(BDR) !
X+K !
140 1.5 150 0.46 -18.2 150 0.46 -18.2
240 1.5 200 0.82 -14.5 200 0.82 -14.5
380 1.5 250 1.28 -11.6 250 1.28 -11.6
550 1.5 300 1.84 -9.2 300 1.84 -9.2
740 1.5 350 2.51 -7.2 350 2.51 -7.2
970 1.5 400 3.27 -5.4 400 3.27 -5.4
19/04/23
56
Open issues / questions
19/04/23
57
Open issues, Questions
RF pickup for cavity ?
3rd test cavity ?
purchase of S-band components: waveguide
CF and LIL flanges, spacers, seals
cooling pipes
high power test test stand
connections to RF, cooling, vacuum system
instrumentation (dimensions, weight, solely linked to test cavity?)
19/04/23
58
19/04/23
58
Thank you very much for your attention
19/04/23
59
EXTRA-SLIDES
19/04/23
60
Accelerating cells geometry
Symbol Cell Parameter
L cell Length
D cell Diameter
g Gap length
RcoOuter Corner Radius
RciInner Corner Radius
RnoOuter Nose Radius
RniInner Nose Radius
CA Cone Angle
S Septum thickness or Web
RbBore Radius
Rco
Rci
Rno
Rni
CA
S/2
L
D/2
Rb
g
19/04/23
61
CABOTO-S
New design will probably be with a different number of cells per tank, in order to increase as much as possible the gradient having in all the structure the maximum allowed ES
'
'
0
0
n
n
E
E
L
ZT
TEnP
2
20
19/04/23
62
35MeV/u
41 48 55 63 71 80 89 99 109 119 130 142 153 166 178 230MeV/u
~ 19 m
204 217191
18 19 201 2 3 4 5 7 8 9 10 11 12 13 14 15 16 176
19/04/23
63
2D cavity optimization
with Superfish
Study of HFSS performance
Why? • To check if HFSS simulations are reliable.• Study of accuracy for determinate mesh size and distribution.
We get:• Appropriate mesh.
3D structure design with
HFSS / GdfidL
Why? • The whole structure can be simulated by these programs.• They provide good calculations for Q-values.
Why? • Superfish gives a good approach to resonant frequencies• Fastest and simplest way to find which geometry provides the maximum ZTT
We get:• Appropriate dimensions of the cavity • Tuning sensitivity (frequency – diameter)
19/04/23
64
19/04/23
64
Parameters 1st TC
Frequency [GHz] 2.9985
= v/c 0.3781
Transit-time Factor 0.8934
Q-value 8690
R/Q [Ohm] 70.311
ZTT [Mohm/m] 67.767
Emax [MV/m] 155.64
Emax [Kilp] 3.32
Emax/E0 6.49
Hmax [A/m] 63709
Hmax [kW/cm2] 2.91
Coupling Coefficient 1.537
Scaling Exponent n 6.779
Change in freq [MHz] 15.85
19/04/23
65
Parameters 2nd TC
Frequency [GHz] 2.9985
= v/c 0.3
Transit-time Factor 0.8934
Q-value 8690
R/Q [Ohm] 70.363
ZTT [Mohm/m] 66.904
Emax [MV/m] 155.63
Emax [Kilp] 3.32
Emax/E0 6.45
Hmax [A/m] 63761
Hmax [kW/cm2] 2.91
Coupling Coefficient 1.522
Scaling Exponent n 6.583
Change in freq [MHz] 18.25
19/04/23
66
Open issues
?
?
?
Characteristics of the experimental bench:
- disposition of cooling, vacuum- disposition of acquisition (solely linked to
prototype?)- where to attach prototype
Thickness of nickel-copper coating (7 μm÷15 μm)
Retrieval of components:- waveguide- flanges (CF, Lil)- pipes and seals
Advice on general mechanical design
19/04/23
67
Open issues: flanges
- Dimensions obtained from straight guide flange (‘CTFARFNE0003’)
- Where to obtain flange seal?
- Do we need to completely machine flange?
- Dimensions of coupling flanges (distance of holes, diameter, possible threading) (SCEM 18.60.18.005.3)
bolted UHV flange (18.60.18.005.3)
remachining
forged blank (18.60.19.070.0)
-Thickness of intermediate see-through seal
Dimensions of intermediate metal seal (18.60.55.850.6)
19/04/23
68
Open issues: cooling
- dimensions of coupling’s pipes- how are pipes normally connected (raccords, threading)- eventually made out of 316L
- coating of tubes 316L (39.36.05)
19/04/23
69