Mechanical design of TD24 11Ghz Damped Sealed Accelerating Structure(based on KEK/SLAC design documentation)

Dmitry Gudkov BE/RF/SR

02 December 20091/14

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Product Elements 1

Tuning system elements

Accelerating elements

Vacuum and interface elements

Cooling system elements

Product Elements 2

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Beam PipeFixed Vacuum Flange

Coupler Assembly With WG90 Flanges

Input Ring Cell

Matching Iris A

Regular Cells

Matching Iris B

Output Ring Cell

Rotatable Vacuum Flange

Regular Cell Disk Mechanical Design

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Interlocking system of disks position

Min. gap = 0.005 mm (KEK/SLAC – 0.01 mm)Max. gap = 0.0125 mm (KEK/SLAC – 0.04 mm)

Reference for assembly – B (Ø74±0.0025)

Assembly Sequence

1. Bonding of all cells of the accelerating structure :

Input Ring CellMatching Iris A

Regular Cells

Matching Iris BOutput Ring Cell

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Photo by Juwen Wang (SLAC)

Pressure: 60PSI = = 60 x 6 894,75729 ≈ 415 kPaTemperature: 1035 °C

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2. Coupler Subassembly:

Brazing of two parts of the coupler using brazing shims:Brazing alloy: Au-Cu 25/75Temperature: 1045 B C

Machining brazed assembly for installationof the vacuum flanges:

Brazing vacuum flanges:

Brazing alloy: Au-Cu 30/70Temperature: 1035 B C

Ph

oto

by

SL

AC

Coupler Cover

Brazing Shim

Coupler Body

Assembly Sequence (continuation)

Assembly of cooling block, caps, tubes:

4 x

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Photo by SLAC

Brazing alloy: Au-Cu 25/75Temperature: 1045 B C

Assembly Sequence (continuation)

Bonded Stack

2 x Coupler Assembly

4 x Cooling Block Assembly

1 x Beam Pipe

104 x Tuning StudsPhoto by SLAC

Au/Cu Alloy: 35/65Brazing temperature: 1020º C

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Brazing 1

Assembly Sequence (continuation)

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Au/Cu Alloy: 50/50Brazing temperature: 979-983º C

Photo by SLAC

Brazing 2: adding second beam pipe

Assembly Sequence (continuation)

TIG WELDING*

10/14* - Tungsten inert gas welding

Assembly Sequence (continuation)

Photo by SLAC

Stud

GuideHummer

Tube

Tuning System

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Tuning System Brazing

1st step: pushing studs to the tuning holeusing special stainless steel pin

2nd step: fastening by wire and special ceramic pins

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Brazing material for tuning stud brazing

1st option: brazing wire ø0.5 mm:

2nd option: Nickel and then Silver plating of the studs:

This plating becomes brazing material.

3rd option: brazing material inside the stud:

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Thanks for your attention!14/14

Used materials:1.SLAC Work Status for the CLIC High Gradient Accelerator Structure R&D, Juwen Wang, CLIC WS 092.CERN production methods, Germana Riddone, CLIC WS 093.Mechanical design of PSI-XFEL X-band structure, D. Gudkov4.KEK, SLAC Accelerating structure documentation5.CERN Accelerating structure documentation

Thanks to: Germana RiddoneAlexander SamoshkinSaid AtiehJuwen WangRiccardo ZennaroAlexey Grudiev

The End