The structural design for a "canted cosine-theta" Superconducting dipole coil and magnet structure-CCT

The Superconducting Magnet Group, at Lawrence Berkeley National Laboratory (LBNL), has been developing a canted cosine-theta (CCT) superconducting dipole coil as well as the coil's supporting magnet structure. This contribution reports on the progress in the development of the coil's winding mandrel and its fabrication options. A comprehensive study of the coil's Lorentz forces was performed to validate the winding mandrel's "stress interception" attributes. The design of the external structure and the application of the "Bladder & Key" technology is also discussed. Additionally, the application of these studies to a curved ion-therapy CCT dipole magnet is reported

Characterization of insulating coatings for wind-and-react coil fabrication

Electrical insulation breakdown between conductor and coil parts and structures is a limiting factor in the performance of high-field magnets. We have evaluated various insulation coatings for possible application in both Nb Sn and Bi-2212 coil fabrication. Such coatings must be robust to maintain structural integrity and provide adequate voltage standoff after the wind-and-react coil fabrication process. Such processes are characterized by reaction temperatures of 650°C in an inert atmosphere for Nb Sn and 890°C in a pure oxygen atmosphere for Bi-2212, and down to cryogenic temperatures when coils are in service. We present a method of testing standardized samples and report the performance characteristics of oxide layers produced (or applied) by plasma-spray, surface conversion, and "paintable" coatings in common areas of voltage breakdown in coil parts. We also address material compatibility and durability during high-temperature heat treatment and cryogenic shock. Suitable coatings selected in the testing process will be instrumental in improving the performance of future wind-and-react coils. © 2014 AIP Publishing LLC. 3

Superconducting ECR ion source: From 24-28 GHz SECRAL to 45 GHz fourth generation ECR.

The development of superconducting ECR source with higher magnetic fields and higher microwave frequency is the most straight forward path to achieve higher beam intensity and higher charge state performance. SECRAL, a superconducting third generation ECR ion source, is designed for 24-28 GHz microwave frequency operation with an innovative magnet configuration of sextupole coils located outside the three solenoids. SECRAL at 24 GHz has already produced a number of record beam intensities, such as 40Ar12+ 1.4 emA, 129Xe26+ 1.1 emA, 129Xe30+ 0.36 emA, and 209Bi31+ 0.68 emA. SECRAL-II, an upgraded version of SECRAL, was built successfully in less than 3 years and has recently been commissioned at full power of a 28 GHz gyrotron and three-frequency heating (28 + 45 + 18 GHz). New record beam intensities for highly charged ion production have been achieved, such as 620 eμA 40Ar16+, 15 eμA 40Ar18+, 146 eμA 86Kr28+, 0.5 eμA 86Kr33+, 53 eμA 129Xe38+, and 17 eμA 129Xe42+. Recent beam test results at SECRAL and SECRAL II have demonstrated that the production of more intense highly charged heavy ion beams needs higher microwave power and higher frequency, as the scaling law predicted. A 45 GHz superconducting ECR ion source FECR (a first fourth generation ECR ion source) is being built at IMP. FECR will be the world's first Nb3Sn superconducting-magnet-based ECR ion source with 6.5 T axial mirror field, 3.5 T sextupole field on the plasma chamber inner wall, and 20 kW at a 45 GHz microwave coupling system. This paper will focus on SECRAL performance studies at 24-28 GHz and technical design of 45 GHz FECR, which demonstrates a technical path for highly charged ion beam production from 24 to 28 GHz SECRAL to 45 GHz FECR

Canted-cosine-theta magnet (CCT)-A concept for high field accelerator magnets

Canted-Cosine-Theta (CCT) magnet is an accelerator magnet that superposes fields of nested and tilted solenoids that are oppositely canted. The current distribution of any canted layer generates a pure harmonic field as well as a solenoid field that can be cancelled with a similar but oppositely canted layer. The concept places windings within mandrel's ribs and spars that simultaneously intercept and guide Lorentz forces of each turn to prevent stress accumulation. With respect to other designs, the need for pre-stress in this concept is reduced by an order of magnitude making it highly compatible with the use of strain sensitive superconductors such as Nb3Sn or HTS. Intercepting large Lorentz forces is of particular interest in magnets with large bores and high field accelerator magnets like the one foreseen in the future high energy upgrade of the LHC. This paper describes the CCT concept and reports on the construction of CCT1 a "proof of principle" dipole

An R&D Approach to the Development of Long Nb3Sn Accelerator Magnets Using the key and Bladder Technology

Building accelerator quality magnets using Nb{sub 3}Sn for next generation facilities is the challenge of the next decade. The Superconducting Magnet Group at LBNL has developed an innovative support structure for high field magnets. The structure is based on an aluminum shell over iron yokes using hydraulic bladders and locking keys for applying the pre-stress. At cool down the pre-stress is almost doubled due to the differences of thermal contraction. This new structure allows precise control of the pre-stress with minimal spring back and conductor over-stress. At present the support structure has been used with prototype magnets up to one meter in length. In this paper, the design of a 4-meter long, 11 Tesla, wind-and-react racetrack dipole will be presented as a possible step toward the fabrication of long Nb{sub 3}Sn accelerator magnets

Nb3Sn Quadrupole Magnets for the LHC IR

The development of insertion quadrupoles with 205 T/m gradient and 90 mm bore represents a promising strategy to achieve the ultimate luminosity goal of 2.5 x 10{sup 34} cm{sup -2}s{sup -1} at the Large Hadron Collider (LHC). At present, Nb{sub 3}Sn is the only practical conductor which can meet these requirements. Since Nb{sub 3}Sn is brittle, and considerably more strain sensitive than NbTi, the design concepts and fabrication techniques developed for NbTi magnets need to be modified appropriately. In addition, IR magnets must provide high field quality and operate reliably under severe radiation loads. The results of conceptual design studies addressing these issues are presented

Mechanical Design of HD2, a 15 T Nb3Sn Dipole Magnet with a 35 mm Bore

After the fabrication and test of HD1, a 16 T Nb{sub 3}Sn dipole magnet based on flat racetrack coil configuration, the Superconducting Magnet Program at Lawrence Berkeley National Laboratory (LBNL) is developing the Nb{sub 3}Sn dipole HD2. With a dipole field above 15 T, a 35 mm clear bore, and nominal field harmonics within a fraction of one unit, HD2 represents a further step towards the application of block-type coils to high-field accelerator magnets. The design features tilted racetrack-type ends, to avoid obstructing the beam path, and a 4 mm thick stainless steel tube, to support the coil during the preloading operation. The mechanical structure, similar to the one used for HD1, is based on an external aluminum shell pretensioned with pressurized bladders. Axial rods and stainless steel plates provide longitudinal support to the coil ends during magnet excitation. A 3D finite element analysis has been performed to evaluate stresses and deformations from assembly to excitation, with particular emphasis on conductor displacements due to Lorentz forces. Numerical results are presented and discussed

Design and Test of a Nb3Sn Subscale Dipole Magnet for Training Studies

As part of a collaboration between CEA/Saclay and the Superconducting Magnet Group at LBNL, a subscale dipole structure has been developed to study training in Nb3Sn coils under variable pre-stress conditions. This design is derived from the LBNL Subscale Magnet and relies on the use of identical Nb{sub 3}Sn racetrack coils. Whereas the original LBNL subscale magnet was in a dual bore 'common-coil' configuration, the new subscale dipole magnet (SD) is assembled as a single bore dipole made of two superposed racetrack coils. The dipole is supported by a new mechanical structure developed to withstand the horizontal and axial Lorentz forces and capable of applying variable vertical, horizontal and axial preload. The magnet was tested at LBNL as part of a series of training studies aiming at understanding of the relation between pre-stress and magnet performance. Particular attention is given to the coil ends where the magnetic field peaks and stress conditions are the least understood. After a description of SD design, assembly, cool-down and tests results are reported and compared with the computations of the OPERA3D and ANSYS magnetic and mechanical models

Fabrication and Test of TQS01 - a 90 mm Nb3Sn Quadrupole Magnet for LARP

In support of the development of a large-aperture Nb3Sn superconducting quadrupole for the Large Hadron Collider luminosity upgrade, two models (TQS and TQC) with a 90-mm aperture are being constructed at LBNL and FNAL within the framework of the US LHC Accelerator Research Program (LARP). These models use two identical Nb{sub 3}Sn coils but have different coil support structures. This paper describes the fabrication, assembly, cool-down and test of TQS01--a model based on key and bladder technology with supporting iron yoke and an aluminum shell. Comparison of the test measurements with design expectations is also reported

Mechanical Analysis of the Nb3Sn Dipole Magnet HD1

The Superconducting Magnet Group at Lawrence Berkeley National Laboratory (LBNL) has recently fabricated and tested HD1, a Nb3Sn dipole magnet. The magnet reached a 16 T field, and exhibited training quenches in the end regions and in the straight section. After the test, HD1 was disassembled and inspected, and a detailed 3D finite element mechanical analysis was done to investigate for possible quench triggers. The study led to minor modifications to mechanical structure and assembly procedure, which were verified in a second test (HD1b). This paper presents the results of the mechanical analysis, including strain gauge measurements and coil visual inspection. The adjustments implemented in the magnet structure are reported and their effect on magnet training discussed