manufacturing process, validation and factory test ess rfq cdr2 2015 12 08-09 bruno pottin

MANUFACTURING PROCESS, VALIDATION

AND FACTORY TEST

ESS RFQ CDR2 2015 12 08-09 Bruno POTTIN

Bruno POTTIN

TABLE OF CONTENTS

1: Copper + HIP

2: Ancillaries

3: Section manufacturing

4: Brazing process

5: Couplers

6: Tuners

7: Acceptance factory test| PAGE 2

Bruno POTTIN

SECTION MANUFACTURING

One RFQ section manufacturing’s steps process

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Bruno POTTIN



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1 Copper + HIP

2 Ancillaries

3 Section manufacturing

4Brazing process

CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

COPPER AND HIP

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Bruno POTTIN

COPPER AND HIP


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Bruno POTTIN

CHOSEN MATERIAL: CU-OFE

• Cu-OFE is chosen for our application (NF EN 13604)• Already used for other RFQ (IPHI, LINAC4, Spiral2)

• Cu-OFE can be machined and brazed « easily »

• Addition of a prevention step: HIP (High Isostatic Pressing)• To avoid porosity / casting defects

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Example of an porosity in IPHIcopper on a brazing plan

Bruno POTTIN

COPPER PROVIDING PROCESS

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Copper OFE• Chemical

composition analysis

3D forging 5 mm peeling Annealing• Grain size• Hardness• Ultrasonic testing

HIPHigh Isostatic Pressing

Manufacturing

Order in progress

Call for tender

Delivery in course

HIP treatment after copper delivery and

before starting machining :

920°C - 1020 bars – 2hArgon gas

HIP treatment process was validated with mock-up

Bruno POTTIN

HIP TREATMENT MOCK-UP

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Assembly by brazingHIP treatment

3 holes : 1,2 and 3 mm diameter

Ø 2 Ø 3Ø 1

Bruno POTTIN

HIP TREATMENT MOCK-UP

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Before

After

After HIP, we have :

- Holes disappeared

Metallographic study :

- Grain size increase- Low hardness

Bruno POTTIN

HIP EQUIPMENT

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HIP treatment in one stepfor all the sections copper

Same copper quality for manufacturing

• 3 possible levels in the oven• Capacity :

• 12 major vanes• 18 minor vanes

• Needed :• 12 major vanes• 12 minor vanes

Major vane

Minor vane

6 sections (5 + 1 spare)


ANCILLARIES

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Bruno POTTIN



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Bruno POTTIN

To avoid machining of the pumping grids on the vanes decrease the machining difficulty

Ancillaries : tuner ports

pick up ports

section flanges

pumping grids

a first correction of the error on the machining of the vanes

before brazing by adjusting the penetration of the pumping

port 2 brazing steps :

• Stainless steel to copper for ancillaries• Copper to copper for module + ancillaries

Using copper No copper coating inside No nickel coating outside No coating simpler Final machining adjustment for brazing on copper

Ancillaries : • Tuner ports : stainless steel with

copper coating inside and nickel

coating outside• Section flanges : stainless steel

with nickel coating• Pumping grids machined directly on

the vane

Technological problem to braze the

stainless steel on the copper

module Brazing copper to copper and

stainless steel to copper in 1 step

MAIN TECHNOLOGICAL CHOICES

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IPHI ESS

IPHI

IPHI

Bruno POTTIN

ANCILLARIES MANUFACTURING

Ancillaries manufacturing’s steps process

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Leak test

Tridimmeasurement

Bruno POTTIN

ANCILLARIES PROCUREMENT : TEST CAVITY

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Mock-up validation of brazing ancillaries on copper cavity as RFQ

Brazing section flange

Brazing tuner port

Brazing coupler port

Brazing pumping grid

Brazing pick up port

Validation with leak test and tridim measurements

The test cavity is useful for the couplers conditioning


SECTION MACHINING

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Bruno POTTIN

IPHI’s project : 4 copper parts per section chosen for ESS


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Machining

Assembly

Brazing copper

parts and ancillaries in vertical position in

1 step

Bruno POTTIN



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Bruno POTTIN


Manufacturer and process validation

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2 major technical phases to be tested in parallel

Schedule and process adaptation to reach the ESS schedule

Deep drilling mock-up

Step1 • Qualification of deep drilling and machining technic• Validation of process and manufacturer capacity with his equipment• Ultrasound test and tridim measurement

Step 2• Qualification of vertical brazing process• Validation of manufacturer brazing process• Tridim measurement and leak test

Brazing mock-up

IPHI

Machining mock-up

Bruno POTTIN


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To start the third step, the steps 1 and 2 must be done

Development plan and validation test according to the qualification phase

Step 3 • Qualification of a total section manufacturing : Section 1• Leak test, tridim and RF measurement

Series production• Sections manufacturing : process adaptation with industrial• Following process to optimize the time• Leak test, tridim and RF measurement

To start the series production, the step 3 must be validated

Bruno POTTIN

SECTION MANUFACTURING VALIDATION


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Tridimmeasurement

Tridim and RF measurement

Specific validation operations will be doneby CEA or with CEA presence

Bruno POTTIN

Brazing

RF validationVacuum leak test validation

Machining


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TriDim


BRAZING PROCESS

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Bruno POTTIN



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2 different brazing

processes

Bruno POTTIN

2 BRAZING PROCESSES

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Two different brazing processes used

Ancillaries manufacturing

• Small pieces (small oven)• Stainless steel-copper brazing without coating• R&D step to industrialize the manufacturing• Many components

Sections manufacturing

• Large pieces (big oven)• Copper-copper brazing• Vertical brazing according to big

geometrical movement due to thermal expansion phenomena

The process (not the same brazing) and the equipment (oven size) are different, not the same resources 2 procurements to reach the ESS schedule

Bruno POTTIN



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• Tridim measurement to check the section• RF measurement• Brazing• Leak test• RF measurement• Tridim measurement

Ancillaries adapted

for brazing


COUPLERS

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Bruno POTTIN

RF loops (coupler : window + loop)

• Same technology as SPIRAL2 (just adaptation)

• Possible use of simple coaxial disc RF window smaller and lighter than waveguide window (easier installation)

• RF losses smaller than with iris+ridge(power budget)

• Faster adjustment and adjustment flexibility(RF tuning success)

SPIRAL2


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COUPLER MANUFACTURING

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Qualification PHASE

• Step 1 : RF window

o Machining and assembly copper-ceramic process

o TiN coatingo Leak test o RF test before and after TiN

coating

• Step 2 : double cooling circuit

o Machining and assembly process

o Leak testo Tridim measurement

Manufacturing of 3 couplers

Bruno POTTIN

COUPLER TEST VALIDATION

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Conditioning of the 3 couplers with the test cavity and the pulsed klystron in the dedicated bunker.

Coupler will be conditioned until 1MW peak power in travelling wave


TUNERS

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Bruno POTTIN


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IPHI ESS

IPHI

Adjustable tuners

• Same geometry during adjustment and operation (same perturbation)

• Definitive position just after adjustment

• No delay of machining between adjustment and final position

• Adjustment possible in operation or after a transport

Adjustement tuners• To do RF tuning

Final tuners for operation• the same dimension

Adapted chock• The correct thickness for each position

along the RFQ• Machining delay between adjustment

and operation Impossibility to change the tuners penetration

Bruno POTTIN

TUNER MANUFACTURING

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One prototype with 2 steps

• Step 1o Bellows qualification after a

thermal treatment according to the brazing process with a multi traction test

o Validation of the welding

• Step 2o Prototype manufacturingo Technological choices

validationo Schedule adaptation for

series production

Qualification of the mechanical comportment under pressure with the test cavity


FACTORY ACCEPTANCE TEST

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Bruno POTTIN

MANUFACTURING TRACKING

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We will follow each step of manufacturing with presence, measurement, report…

• Processes and methods used for manufacturing (deep drilling, machining and brazing)

• Operating conditions

• Tools for handling and manufacturing

• Stabilization for machining (T°, power supply, vibration, calibration, maintenance, oil type …)

• Thermal treatment and brazing : oven characteristics and temperature curve • Cleaning process

• Storage for the delivery but also during machining

• Technical specifications to sub-contractors

• …

LEAK TEST

Vacuum leak test validation According to the ESS handbook

Contract approach:We specify this requirement in specifications :During the vacuum test, every leak over 10-10 mbar.l/s must be repared

Technologic approach:Study of the leak’s impact (Vacuum, RF…)ESS-CEA analysisRepair or not?Repair consequences : risks, cost and delay

It’s a choice between a slightly degraded component or to repair with risks

OTHER ACCEPTANCE TESTS

Tridim measurement Tuning RF measurement

• Dimension validation• Displacement qualification

• Cavity RF characteristics validation


THANK YOU

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Bruno POTTIN

The ESS RFQ: 5 x Sections (L= 0.92m) for a total length = 4.58m 2 x Vacuum ports per quadrant and per section except on S3 (hosting the

2 RF couplers) 32 3 x 80mm-diameter pistons per quadrant and per section acting as tuners

60 Pick-up ports 28 8 x 10mm-diameter cooling channels per section (variable length) RFQ in CuC2 and Flanges in stainless steel

Global Schematic view of ESS RFQ

S1

S5

S2S3

S4

THE ESS RFQ MECHANICAL DESIGN

View of the end section of the RFQ with the tuning rod for a

quadrant

Transversal view of the RFQ across the tuners

40mm

Cooling channels

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manufacturing process, validation and factory test ess rfq cdr2 2015 12 08-09 bruno pottin

Documents

hip page

copper modulebrazing

copper ancillaries

bruno pottin hip treatment

bruno pottin assembly

bruno pottin example

copper cavity

sections copper