The superconducting coupling solenoid to be applied in the Muon Ionization Cooling Experiment (MICE) is made from copper matrix Nb-Ti conductors with inner radius of 750 mm, length of 285 mm and thickness of 102.5 mm at room temperature. The magnetic field up to 2.6 T at the magnet centerline is to keep the muons within the MICE RF cavities. Its self inductance is around 592 H and its magnet stored energy is about 13 MJ at a full current of 210 A for the worst operation case of the MICE channel. The stress induced inside the coil during cool down and charging is relatively high. Two test coils are to build and test in order to validate the design method and develop the fabrication technique required for the coupling coil winding, one is 350 mm inner diameter and full length same as the coupling coil, and the other is one-quarter length and 1.5 m diameter. The 1.5 m diameter coil will be charged to strain conditions that are greater than would be encountered in the coupling coil. This paper presents detailed design of the test coils as well as developed winding skills. The analyses on stress in coil assemblies, AC loss, and quench process are carried out

Chen, AnBin

Gou, XingLong

Green, Michael

Li, Darun

Li, LanKai

Liu, XioaKun

Pan, Heng

Strauss, Bruce

Wang, Li

Wu, Hong

Xu, F.Y.

UNT Digital Library

IEEE Transactions on Applied Superconductivity 19, No. 3,                           MICE Note 233 LBNL-ccccE 1 Abstract—The superconducting coupling solenoid to beapplied in the Muon Ionization Cooling Experiment (MICE) ismade from copper matrix Nb-Ti conductors with inner radius of750 mm, length of 285 mm and thickness of 102.5 mm at roomtemperature. The magnetic field up to 2.6 T at the magnetcenterline is to keep the muons within the MICE RF cavities. Itsself inductance is around 592 H and its magnet stored energy isabout 13 MJ at a full current of 210 A for the worst operationcase of the MICE channel. The stress induced inside the coilduring cool down and charging is relatively high. Two test coilsare to build and test in order to validate the design method anddevelop the fabrication technique required for the coupling coilwinding, one is 350 mm inner diameter and full length same asthe coupling coil, and the other is one-quarter length and 1.5 mdiameter. The 1.5 m diameter coil will be charged to strainconditions that are greater than would be encountered in thecoupling coil. This paper presents detailed design of the test coilsas well as developed winding skills. The analyses on stress in coilassemblies, AC loss, and quench process are carried out.Index Terms—MICE magnet, stress, AC losses, quench,winding system, cool down testI. INTRODUCTIONHE international Muon Ionization Cooling Experiment(MICE) will be a demonstration of muon cooling in aconfiguration of superconducting solenoid magnets andabsorbers that may be useful for a future neutrino factory [1].A pair of coupling magnets is applied to produce up to 2.6 Ton the magnet centerline to keep the muon beam within thethin RF cavity windows. The peak field of the coupling coil isup to 7.4 T at the worst case and the operation temperaturemargin of the magnet is only about 0.8 K [2].Because of high magnetic field and large size of thecoupling magnet, the stress inside it is relatively high duringcool down and full charging. When applying winding pre-stresses of 70 MPa on the coil, the hoop stress at the outmostlayer of coupling coil is in tension about 103 MPa afterManuscript received 19 August 2008. This work was supported by Fundsof cryogenics and superconductivity technology innovation project under“985-2 Plan” of Harbin Institute of Technology. This work was also supportedby the Office of Science, US Department of Energy under DOE contract DE-AC02-05CH11231. DOE funding of the US Neutrino Factory Muon ColliderCollaboration is greatly appreciated.L. Wang, H. Pan, F. Y. Xu, et al. are with the Institute of Cryogenics andSuperconductive Technology, Harbin. Institute of Technology, Harbin150001, China (e-mail: WangLi_icst@hit.edu.cn). M. A. Green and D. R. Liare with Lawrence Berkeley National Laboratory, Berkeley, CA, 94720 USA(e-mail: magreen@lbl.gov). B. P Strauss is from the Office of Science, USDepartment of Energy, Germantown MD, USAcharged to full current of 210 A, and the peak Von Misesstress is about 151 MPa which appears at the centre of theoutmost layer.Two test coils were designed and under constructing inorder to validate the magnet design method and develop thefabrication technique for coil winding. The two test coilsadopted the copper matrix NbTi conductors with the cross areaof 1.65x1.00 mm2, which is same as the MICE couplingmagnet. The small test coil is 350 mm inner diameter with fulllength of 285 mm as the coupling coil but only 20 layers; thelarge test coil is 1.5 m inner diameter with one-quarter lengthof the coupling coil and the same layers of 96 as coupling coil.All the skills to be used for fabricating the coupling coil willbe performed on the two test coils.II. DESIGN FOR TEST COILSThe small coil is to be used for testing and debugging thewinding machine and the soldering skills for conductor spliceswhile winding. The large coil is to be used for simulating thestress and strain conditions that would be encountered in thecoupling coil [3]. The material of the two test coils’ mandreland cover plate is 6061-T6 aluminum alloy, and the banding ismade from 316 stainless steel wire.When the coupling coil at the worst case which is chargedat 210 A, the operation temperature margin is about 0.8 K,according to the load line shown in Fig. 1. For small coil andthe large coil, in order to fulfill the objective to simulate thestress situation, and with the same temperature margin, thehighest current is about 500 A and 350 A respectively.  Thebasic parameters for two test coils are listed in Table I and theschematic of their cross sections are in Fig. 2.Fig. 1.  The load line for small coil, large coil and coupling coilDesign and Construction of Test Coils for theMICE Coupling Solenoid MagnetL.Wang, H.Pan, F.Y.Xu,  X.K.Liu, A.B.Chen, L.K.Li, X.L.Guo, H.Wu,M. A. Green Member IEEE, D. R. Li, and B. P. Strauss Sr. Member IEEETIEEE Transactions on Applied Superconductivity 19, No. 3,                           MICE Note 233 LBNL-ccccE 2TABLE I THE BASIC PARAMETERSParameters SmallCoilLargeCoilCoil Length (mm) 285 72Coil Inner Radius (mm) 175 750Coil Thickness (mm) 25.5 102.5Number of Layers 20 96No. Turns per Layer 166 42Magnet J (A mm-2) 95.9 114.6Magnet Self Inductance (H) 3.14 50.8Peak Induction in Coil (T) 2.33 3.93CoilBandingG-10 CoilBandingG-10Fig. 2a Small coil Fig. 2b Large coilA. The analyses on stresses in the two coil assembliesThe FEA model used for stress simulation during theprocesses of coil winding, cool down and full chargingincludes the coil, mandrel, banding, G-10 insulations andcover plate as shown in Fig. 2. The winding pre-stress on theconductor is set as 70 MPa and 60 MPa on the banding. Table II shows the simulation results for the coils. For thelarge coil, after winding the coil onto the mandrel, the tensilehoop stress at its outmost layer is about 55.9 MPa, which isclose to the pre-stress of 70 MPa impacting on the conductorby divided by fill factor 0.78. So the numerical result is inagreement with actual winding process. During cool downfrom 300 K to 4.2 K, the peak compressive stress is ~107 MPain the inner center of the coil. The tensile stress on the outmostlayer is about 22 MPa. After charged to full current, the peaktensile hoop stress is about 80 MPa on the outmost layer. Thecompressive hoop stress in the inner central surface is almostzero. The peak von Mises stress is about 131 MPa, whichappears at the centre of the outmost layer. Because of thebobbin of the coupling coil is longer than that of larger coil, sothe von Mises stress of the coupling coil is a little higher thanthe large coil during winding.TABLE II  STRESSES IN THREE COILSPre-winding Cooling ChargingParameter(MPa) S* L* C* S L C S L CHoop ** 54.7 55.9 54.2 20 22 46 50 80 103Radial**-3 -2.1 -2.4 -2.4 -10.3 -3.9 -4.4 -8.2 -1.1 Max.Shear  5.19 7.6 7.8 40.4 63 51.4 35.4 54.6 39.3Max.VonMises 71 55.1 104 83.7 118 126 111 131 151*S is small coil, L is large coil and C is the coupling coil, ** Hoop stress is thevalue on the outermost layer; Radial stress is the value in the inner layer.From Table II, it appears that the maximum stresses in thelarge coil at 350 A are close to the maximum stress for thecoupling coil. If the large test coil can be operated at or nearthe 4.2 K short sample current, the peak stresses in the largecoil will be higher than the design stresses for the MICEcoupling magnet at its maximum current.B. AC losses in test coilsIn order to calculate hysteretic AC loss more accurately, thecross-sections of two test coils were divided into five regionsand the charging process was divided into four time steps, andthe results were summarized in Table III and Table IV [4].TABLE III  AC LOSSES IN SMALL COILTime (s) Hysteretic Loss (W) Mandrel Loss(W) AC loss (W)450  0.0947 0.0025 0.09721350   0.0691 0.0025 0.07162250 0.0523 0.0025 0.05483150 0.0415 0.0025 0.0440TABLE IV  AC LOSSES IN LARGE COILTime (s) Hysteretic Loss (W) Mandrel Loss(W) AC loss (W)450 1.378 0.056 1.4341350 0.770 0.056 0.8262250 0.497 0.056 0.5533150 0.374 0.056 0.43Both test coils will be cooled by liquid helium in coolingtubing by means of thermo-siphon principle. Compared withthe available cooling capacity, the AC losses are negligible.C. Quench process in test coilsThe quench protection for test coils is designed as thepassive protection. The technology of subdivision and quench-back is adopted in order to reduce the inner voltage and thehot-spot temperature [5][6][7]. The quench protection of thesmall coil is subdivided into two subsection using 0 Ωresistors; the large coil is subdivided into four sections asshown in Fig. 3. Each subsection consists of a pair of back toback diodes and a resistor. The simulation results of quenchprocess for the two coils are listed in the Table V. The peakinternal voltage is less than the allowable breakdown voltageof electrical insulation between layers.TABLE V SIMULATION RESULTS OF QUENCH PROCESSParameters Small Coil LargeCoilThe hot spot temperature (K) 113 117The peak internal voltage(V) 885 1973IEEE Transactions on Applied Superconductivity 19, No. 3,                           MICE Note 233 LBNL-ccccE 3Fig.3. The quench protection scheme for large coilIII. WINDING SKILLS FOR TEST COILSA. Winding SystemFig. 4. The layout of solenoid magnet winding machineA set of winding system for the solenoid magnet was builtin ICST as shown in Fig. 4. The winding system mechanicallyconsists of a winding machine, an automatic guider, a tensionadjusting mechanism, and a dereeler (a facility that unwindsconductor from the spool) [3]. The developed technology forthe winding machine includes; variable winding speed, highaccuracy wire alignment, and constant tension control. TheICST winding facility has capabilities of winding small andmedium sized solenoid coils. The automatic guider canprovides turn-to-turn stepping distance of 1.717 mm per turnof the main shaft during the winding of the coupling coil. Thedesigned tension range for the winding machine will be of50~350 N, because tension adjusting mechanism depends onthe set of movement masses. The dereeler will work alongwith the tension adjusting mechanism to provide constanttension control for the coil winding or unwinding. Thefunction modules such as automatic guider and tensionadjusting mechanism are movable and the relative position ofthe modules will depend on the coil size to be wound.B. Small Coil WindingElectrical insulations must be applied between the coil toground or mandrel, between coil layers, and between the coiland banding. For ground insulations, two layers of G-10 sheetswith 0.5 mm of thickness each were wrapped onto thecylindrical 6061-aluminum mandrel with Stycast epoxy. Thecoil end insulation consists of two G-10 plates with a totalthickness of 3 mm that were glued onto end plates of the coilmandrel. The coil to mandrel insulation should pass 5 kVhipot test and the leak current should be less than 50 A.Fig. 5  Winding of small coilThe insulations between layers are composed of fiberglasscloth and epoxy as shown in Fig. 5. Once the first layer iswound, the fiberglass cloth with 0.1 mm of thickness iswrapped over it, and then to brush the epoxy and winding theconductor for the next layer. The thickness per layer iscontrolled within 1.24 mm and should be evenly.Banding with pre-tension winding on the coil will providesome hoop force support and ensure the coil is tightly packedwhen it is cooled down. The brass wire of 1.7 mm in diameterwas used to band the coil, and the starting end and the tail endwere connected together by soldering in order to maintain thetension.According to the FEA simulation, the pre-stress of 70 MPais applied for both test coils during winding. The pre-tensionapplied on the coil banding is 60 MPa, and the actualthickness of the banding for the small coil is 7 mm with 4layers of brass wires. The coil will be further insulated by twolayers of 0.5 mm thick G-10 sheets with epoxy beforebanding. Two layers of Kapton film with a thickness of 0.02mm were glued into the corners of mandrel end plates andoutside the G-10 insulation system in order to enhance theelectrical insulation in those regions.C. Superconducting JointsIn the small test coil, there are two superconducting joints.The large coil may have 5 to 6 splices (also referred to asjoints). The full MICE and MuCOOL coupling coils may haveas many as a dozen splices within the coil.Two types of overlap soft solder lap joints have beenstudied and made by ICST for the MICE coupling coils andtest coils, which are the up-down lap joints and the side-by-side joints. The up-down lap joints can only be placed at theends of the coil, so there will be no turns lost in one coil layer.The side-by-side joints can be made in the middle of the layerin magnet coils, so less conductor will be thrown away in thewinding process. Two kinds of low melting point soft solder,Sn63Pb37 and Ag3.5Sn96Cu0.5, were tested for each joint type aswell. The overlap length of all splices is about 1 m. Theeffects of the solder and the magnetic field on the spliceresistance were tested in LBNL as shown in Table VII andFig. 6. Measurements were done on a center section of 0.25 mlong as well as the full splice length. The results normalized toa splice length of 1-meter [8].The splice resistance of side-by-side joints is not verydifferent from the resistance of up-down joints and thenormalized resistances of  both types of joints are in the rangeof 0.7 nΩ  to 1.7 nΩ . The resistance does not appear toincrease rapidly with magnet fields. The data in Fig. 6 andFiber glassEpoxySC coilIEEE Transactions on Applied Superconductivity 19, No. 3,                           MICE Note 233 LBNL-ccccE 4Table VI suggests that the resistance of the Ag3.5Sn96Cu0.5joints may be lower than for the Sn63Pb37 joints, but thedifference between the two solders seems more pronouncedfor the side-by-side joint. The selection of the solder for thejoint should be based on other factors such as strength andsusceptibility to tin rot at low temperatures, which will befurther studied later.TABLE VI NORMALIZED SPLICE RESISTANCE AT B=1TSplice Type Type of Solder SpliceLengthNormalizedResistance(n_)Up-down Ag3.5Sn96Cu0.5 1.02 m 1.08Side-by-side Ag3.5Sn96Cu0.5 1.00 m 1.17Up-down Sn63Pb37 1.04 m 1.25Side-by-side Sn63Pb37 1.00 m 1.54Fig. 6  Two types of splice resistance as a function of  magneticinduction for the length of 1.0 mIV. THE LN2 COOL DOWN RESULTS OF SMALL COILThe LN2 cool down test is executed after winding the smallcoil to test the uniformity of temperature in the coil duringcool down, the electricity performance, and the ability ofenduring to thermal stress. The mainly facilities consists of a500 L LN2 dewar, a test cryostat, cooling pipelines,mechanical and turbo molecular pump group, and regulatingvalves. During the cool down of the coil, the maximumdifference of temperature on the coil was controlled no higherthan 30 K and the cool down speed was less than 30 K/hour toprotect the coil from thermal crack. The vacuum of cryostat iskept at 1.6x10-2 Pa during cooling down, and from roomtemperature to 77 K, and it took about 4 hours.The measured resistance of the small coil is fit well with thecalculation at low temperature as shown in Fig. 7. Thedifference of measured results and calculation results nearroom temperature is about 5 ohms. This may be because theactual length of the conductor in the coil is longer than thelength was calculated. Fig.7. The resistance of small coil during cooling downThe cryogenic test facility for the test coils and MICEcoupling coils was still under construction in ICST at the timethis report was written. Once the cryogenic system is built, theelectrical and cryogenic performance of the two test coils willbe measures. The results of these tests will be reported on, infuture report.V. CONCLUSIONThe design work for two test coils were carried out for theMICE coupling magnet system. The small coil was fabricatedand cooled to liquid nitrogen temperature by ICST. Tests athelium temperature will occur when the cryogenic test systemconstruction is finished. The large test coil is underconstruction at ICST. The design method for the couplingmagnets will be validated by the test coils. The skills neededfor fabricating the coupling coil will also be validated on thesmall and large test coils before the report is published.REFERENCES[1] G. Gregoire, G. Ryckewaert, L. Chevalier, et al, “MICE andInternational Muon Ionization Cooling Experiment Technical ReferenceDocument”, [on line] http://hep04.phys.itt.edu/cooldemo.[2] L. Wang, M. A. Green, F. Y. Xu, et al, “The Engineering Design of the1.5m Diameter Solenoid for the MICE RFCC Modules”, IEEETransactions on Applied Superconductivity 18, No. 2 p 937-940 (2008).[3] Institute of Cryogenics and Superconductivity Technology,“Engineering Design of MICE/MUCOOL Coupling Solenoid Magnet”,Harbin Institute of Technology, CHINA (2007).[4] Green, M. A., Wu, H., Wang, L., L., L. Kai, Jia, L. X. Yang, S. Q., “ACLosses in the MICE Channel Magnets Is This a Curse of a Blessing?”,LBNL-63804 and MICE Note-195, (2008).[5] M. A. Green and H. Witte, “Quench Protection and Power SupplyRequirements for the MICE Focusing and Coupling Magnets,” LBNL-57580, 8 May 2005.[6] M. A. Green, L. Wang, X. L. Guo, et al “Quench Protection for theMICE Cooling Channel Coupling Magnet”. LBNL-63698, 31 January2008.[7] X. L. Guo, F.Y. Xu, L. Wang, M. A. Green, et al “Quench Protection forthe MICE Cooling Channel Coupling Magnet,” submitted to IEEETransactions on Applied Superconductivity 19, August 2008.[8] Michael A. Green, Dan Dietderich, Hugh C. Higley, et al, “TheCalculated and Measured Resistance for Joints between Conductors in aMICE Superconducting Coil”, MICE Note (July 2008), to be published.IEEE Transactions on Applied Superconductivity 19, No. 3,                           MICE Note 233 LBNL-ccccE 5DISCLAIMERThis document was prepared as an account of work sponsored by the United States Government.While this document is believed to contain correct information, neither the United StatesGovernment nor any agency thereof, nor The Regents of the University of California, nor any oftheir employees, makes any warranty, express or implied, or assumes any legal responsibility for theaccuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed,or represents that its use would not infringe privately owned rights. Reference herein to any specificcommercial product, process, or service by its trade name, trademark, manufacturer, or otherwise,does not necessarily constitute or imply its endorsement, recommendation, or favoring by the UnitedStates Government or any agency thereof, or The Regents of the University of California. The viewsand opinions of authors expressed herein do not necessarily state or reflect those of the United StatesGovernment or any agency thereof, or The Regents of the University of California.

Design and Construction of Test Coils for the MICE Coupling Solenoid Magnet

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Design and Construction of Test Coils for the MICE Coupling Solenoid Magnet

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