results of short module and qualification strategy

Results of short module and qualification strategy

PIMS production meeting 26-27 February 2013

Rolf Wegner

PIMS production meeting 26-27 February 2013 Rolf Wegner 2

Production qualification, April 2012Status of machining qualification, 19.04.2012:

Step std + central disc

end disc(cooling ch.)

ring by milling

ring by turning

WG-ring

1st rough (+2mm)

ok(10.01.2012)

ok(10.01.2012)

ok(10.01.2012)

ok(19.04.2012)

brazing test => horizontal or vertical brazing ?

2nd rough (+1mm)

ok(30.03.2012)

ok(30.03.2012)

Ring G_13-14:

serious non-conformities=> repair of EB-weld

Ring G_1-2: serious non-conformities=> machining tests

3rd rough(+0.2mm),

final

Full Quality Assurance Report+ check at CERN





26.02.2013


Review of steps towards qualification

26.02.2013

•Meeting at CERN in March 2012:

* machining procedures optimised (=> clamping) [parts seen 5 to 10 times out of tolerance]

* specifications very tight; small performance degradation <=> accepting certain deviations from specifications (EDMS 1209460)

* recommendation: final machining on a lathe

•Meeting at NCBJ in April 2012:

* green light for rough machining of discs for series

* Quality Assurance Report form defined

•Mai 2012:

* new weld qualification with cosmetic pass + repair of weld for ring G_13-14

* preliminary metrology end disc M_1 => green light to finish end disc M_14 and disc M_6-7

•June 2012:

* brazing test finished



26.02.2013

•July 2012:

* QA report disc G_2-3 ok, end disc M_1 ok, shipment to CERN

* QA report disc M_6-7, re-machining of assembly ø524 requested

* QA report end disc M_14, agreed on adaptation of ring M_13-14 - side 14 for assembly ø524

•September 2012:

* welding of ring M_13-14 ok, defect on ring M_1-2 => sent for repair to Julich=> using ring G_13-14 as 2nd ring for short module

* brazing test evaluated at CERN (visual inspection, ultrasound & vacuum tests), very good result, => green light to produce waveguide ring cavity M

* disc G_2-3, end disc M_1 inspected at CERN => green light for finishing all discs cavity M

•November 2012:

* QA report ring M_13-14



26.02.2013

•December 2012:

* QA report re-machined ring G_13-14 => green light for finishing all rings cavity M

* end disc M_14, disc M_6-7, ring M_13-14 and ring G_13-14 arrived at CERN

•January 2013:

* QA report discs M_2-3, M_12-13

•February 2013:

* QA report discs M_4-5, M_10-11


Quality Assurance Reports

26.02.2013

•=> "Disc G_2-3 - Analysis & Comparison CERN.xlsx"

* report form from NCBJ exactly as desired

* analysis to specifications

* analysis to acceptable dimensions

* comparison to CERN measurements

•metrology machine accuracy: ± 6 μm

=> comparison precision: ± 12 μm

=> specifications 500 mm ± 10 μm difficult to machine and difficult to measure !!!

results quite similar (a few small points to discuss tomorrow)


Vacuum tests at CERN

26.02.2013

end discs M_1, M_14; disc G_2-3; ring M_13-14 all leak rate < 2*10-11 mbar*l/s


Brazing test at NCBJ

26.02.2013

• good visual impression

• vacuum tight (leak rate <1*10^-10 mbar l/sec)

• good ultrasound analyse results

• Agostino: ”It is hard to do it better”

=> Green light for brazing of WG ring of 1st cavity (25.09.12)


Machined parts, end discs M_1 and M_14

26.02.2013

element EDMS remarks slight deviations* serious deviations* where leak tight

cavity suited

end disc M_1

1243403 surf. roughness <0.8

Ø524: gap +16 μmcooling channels (wall >5.0mm)survey hole 1 8H7 8.37 mm but NCBJ and CERN metrology deviate ≤ 54 μm

none CERN yes yes,ready

end disc M_14


scratches, craters⌾Ø518: +33 μmnose position: +10 μmØ524: gap -31 μm => adjacent ring opened by 30 μmcooling channels (wall >5.0mm)some holes too short (1.. 2 mm)

⌾Ø524: +74 μm CERN yes tbd,ready

* to acceptable dimensions


Machined parts, disc M_6-7

26.02.2013


cavity suited

disc M_6-7

1253702 scratches, craters⌾Ø518: +43 μm / +16 μmØ524: gap -5 μm / 57 μm⌾Ø524: +20 μm / 26 μmØ538: +25 μm / + 23 μmnose length: -5 μm / +12 μmnose position: +19 μm / 35 μmcoupling slot symmetry & R15cooling channels (wall >5.0mm)

surf. roughness nose cone 1.0 to 2.8 μm side 7burrs on all cooling channels => to be re-machined

CERN



Machined parts, ring M_13-14

26.02.2013


cavity suited

ringM_13-14

1252346 side 14 well opened for end disc M_14circularity 0.04 / 0.08 with 2 max/min

⌾Ø538: +2 μm / +19 μmsurf. roughness inside 1.4 μm => 1.2% more RF losses

⌾Ø524: +51 μm / +104 μm

CERN YES tbd,ready



Machined parts, disc G_2-3

26.02.2013


cavity suited

disc G_2-3


Ø538: +23 μm / + 19 μmnose length: +18 μmflatness nose tip: 47 μm

CERN YES YES,ready



Machined parts, ring G_13-14

26.02.2013


cavity suited

ringG_13-14

1252344 machining tests

many flatness @ welds: 87 μm / 75 μmB A:⊥ 0.114 (0.3 all cavity)

NCBJ nobut ok for short module


• Ring G_13-14 was intended for machining tests to validate milling technology (spare material of CERN prototype)

• port welding defect, weld was repaired, further machining tests

• port welding defect of ring M_1-2, ring G_13-14 is used for assembly check of short module


Machined parts, summary

26.02.2013

• discs analysed are close to acceptable dimensions=> remarkable progress made since last year (improvement of factor 5 to 10 on most tolerances) assembly diameter 524.720-0.025

+0 seem to be well under control (QA reports discs M_2-3, M_4-5, M_10-11, M_12-13)however, deviations on * coaxiality axis/524/538mm (=> inter-cavity alignment – aperture reduction)* perpendicularity axis/faces (=> inter-cavity alignment – aperture reduction)* cooling channel finishing

=> we need to analyse remaining discs of cavity M at CERN for qualification

• ring M_13-14 is close to acceptable dimensions=> remarkable progress made since last year (machining procedures were developed [weld deformation] and most acceptable tolerances reached) assembly diameter 524.720+0.050

+0.075 seem to be well under control (also ring G_13-14)however, deviations on * coaxiality 538/524mm (=> inter-cavity alignment – aperture reduction)* perpendicularity axis/faces (=> inter-cavity alignment – aperture reduction)* only 1 ring as sample

=> we need to analyse remaining rings of cavity M at CERN for qualification


Short module: assembly test

26.02.2013

• assembly was very smooth

• only end disc M_14 was slightly difficult to place correctly, small gap remains=> Thierry will use dense point weldings before final weld

end disc M_1

ring G_13-14

disc G_2-3

ring M_13-14

end disc M_14


Short module: RF check, preliminary results

26.02.2013

measured simulated freq. difference[kHz]

ratio meas/sim[%]

f_mode_1 [MHz] 349.756 350.500 -744

Q_mode_1 21'500 26'560 80.9

f_mode_2 [MHz] 363.308 363.970 -662

Q_mode_2 27'730 30'200 91.8

0 50 100 150 200 250 300 350 400 450 500

-0.20

0.00

0.20

0.40

0.60

0.80

1.00|Ez|^2

Mode 1, simulatedMode 1, measured

0 50 100 150 200 250 300 350 400 450 500

-0.20

0.00

0.20

0.40

0.60

0.80

1.00|Ez|^2

Mode 2, simulatedMode 2, measured

z-axis: assembly order z=0 end disc M_1 - ring G_13-14 - disc G_2-3 - ring M_13-14 - end disc M_14 … to z=max


Short module: RF check, preliminary results

26.02.2013

• assembly had to be clamped, otherwise Q ~ 1'000, f_mode_1 ~ 349.200 MHz

• Q-values reasonable, will improve with welding (~ 10% seen for prototype)

• field profiles look very similar, slight deviations for mode 2

• ~ 700 kHz frequency difference between measurement and simulations

• simulation uncertainty ~ ± 500 kHz (mesh limit, 2 cells, different geometry)

• tuning range (island + plunger) for mechanical tolerances + simulation uncertainties: ± 600 kHz

=> further analysis needed to understand difference in frequency simulations/measurement

=> simulation model needs to be checked carefully (systematic difference 700 kHz)

measured simulated freq. difference[kHz]

ratio meas/sim[%]

f_mode_1 [MHz] 349.756 350.500 -744

Q_mode_1 21'500 26'560 80.9

f_mode_2 [MHz] 363.308 363.970 -662

Q_mode_2 27'730 30'200 91.8


Next steps

26.02.2013

•qualification of vacuum check

* visit of NCBJ experts to CERN, March 25-26th, tests of end disc, disc, ring

* shipment of equipment to NCBJ (~ 100 kg, ~ 200 pieces, ~ 25'000 CHF)

* visit to NCBJ with CERN experts, intended before April 19th (material !)tests of end disc, disc, ring

•vacuum check of discs and rings cavity M at NCBJ

•production and checks of waveguide ring cavity M at NCBJ

•check of discs and rings cavity M at CERN => qualification for series production

•check of waveguide ring cavity M at CERN => qualification for series production

•in order to advance production, maybe intermediate green light for finishing cavity 2


Production qualification, February 2013Status of qualifications, 25.02.2013:

Step std + central discs end discs rings WG-rings

1st rough (+2mm) ok(10.01.2012)

ok(10.01.2012)

ok(19.04.2012)

ok(25.09.2012)

2nd rough (+1mm)

ok(30.03.2012)

ok(30.03.2012)

ok(18.12.2012)

ok(25.09.2012)

final for cavity 1 (M)

ok(27.09.2012)

ok(10.05.2012)

ok(18.12.2012)

ok(25.09.2012)

final for cavity 2

vacuum check at NCBJ

final for series check discs cavity 1 (M) at CERN

check discs cavity 1 (M) at CERN

check rings cavity 1 (M) at CERN

check WG-ring cavity 1 (M) at CERN

26.02.2013

results of short module and qualification strategy

Documents

qa report ring

qa report disc g

qa report end disc

qa report discs

qa report remachined

welding of ring

adaptation of ring

waveguide ring cavity