Engineering topics

Vallone, G.

Publications and source records attributed to Vallone, G..

At least 19 records

DOE OSTI2024

First results of AUP Nb3Sn quadrupole horizontal tests

The Large Hadron Collider will soon undergo an upgrade to increase its luminosity by a factor of ~10 [1]. A crucial part of this upgrade will be replacement of the NbTi focusing magnets with Nb3Sn magnets that achieve a ~50% increase in the field strength. This will be the first ever large-scale implementation of Nb3Sn magnets in a particle accelerator. The High-Luminosity LHC Upgrade, HL-LHC is a CERN project with a world-wide collaboration. It is under construction and utilizes Nb3Sn Magnets (named MQXF) as key ingredients to increase tenfold the integrated luminosity delivered to the CMS and ATLAS experiments in the next decade. The HL-LHC AUP is the US effort to contribute approximately 50% of the low-beta focusing magnets and crab cavities for the HL-LHC. This paper will present the program to fabricate the Nb3Sn superconducting magnets. We are reporting the status of the HL-LHC AUP project present the results from horizontal tests of the first fully assembled cryo-assembly.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

AUP First Pre-Series Cryo-Assembly Design Production and Test Overview

New high field and large-aperture quadrupole magnets for the low-beta inner triplets (Q1, Q2, Q3) have been built and tested as part of the high-luminosity upgrade of the Large Hadron Collider (HL-LHC). These new quadrupole magnets are based on Nb3Sn superconducting technology. The US Accelerator Upgrade Project (US-AUP) is producing the Q1 and Q3 Cryo-Assemblies: a pair of ~5 m long magnet structures installed in a stainless-steel helium vessel (Cold Mass) and surrounded by cryostat shields, piping, and a vacuum vessel. In conclusion, this paper gives an overview of the design, production, and the results of the horizontal test of the first pre-series Q1/Q3 Cryo-Assembly.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Magnets for a Muon Collider—Needs and Plans

We describe the magnet challenges for a Muon Collider, an exciting option considered for the future of particle physics at the energy frontier. Starting from the comprehensive work performed by the US Muon Accelerator Program, we have reviewed the performance specifications dictated by beam physics and the operating conditions to satisfy the accelerator needs. Among the many magnets that make up a muon collider, we have identified four systems that represent well the envelope of challenges: the target and capture solenoid, the final cooling solenoid, the accelerator dipoles and the collider dipoles. These systems provide focus for the development of novel concepts, largely based on HTS for reasons of performance, cost and sustainability. After giving a consolidated overview of the needs for the magnet systems, we describe here the basic technology options considered, and the plan for design and development activities.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Analysis of the MQXFA Low Beta Quadrupoles for HL-LHC after 50% magnet assembly complete +

The US HL-LHC Accelerator Upgrade Project (AUP) is fabricating the MQXFA magnets to be used in the Q1 and Q3 Inner Triplet elements of the High Luminosity LHC (HL-LHC). This is the first production of Nb3Sn magnets for a particle accelerator, together with the MQXFB magnets for Q2a and Q2b. Here we show status and some results of MQXFA magnets fabrication and vertical test.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Conceptual Design of a 20 T Hybrid Cos-Theta Di- pole Superconducting Magnet for Future High-Energy Particle Accelerators

High energy physics research will need more and more powerful circular accelerators in the next decades. It is therefore desirable to have dipole magnets able to produce the largest possible magnetic field, in order to keep the machine diameter within a reasonable size. A 20 T dipole is considered a desired achievement since it would allow the construction of an 80 km machine, able to circulate 100 TeV proton beams. In order to reach 20 T, a hybrid Low-Temperature Superconductor (LTS) - High-Temperature Superconductor (HTS) magnet is needed, since LTS technology is presently limited to ~16 T for accelerator magnet applications. In this paper, we present the design of a 6 layers 20 T hybrid dipole magnet using Nb3Sn (LTS) and Bi2212 (HTS). We show that it is possible to achieve this magnetic field with accelerator field quality, with sufficient margin on a realistic conductor, keeping the stresses within safe limit, avoiding conductor degradation

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Optimizing the use of pressurized bladders for the assembly of HL-LHC MQXFB magnets

The use of pressurized bladders for stress control of superconducting magnets was firstly proposed at Lawrence Berkeley National Laboratory in the early 2000s. Since then, the so-called ‘bladders and keys’ procedure has become one of the reference techniques for the assembly of high-field accelerator magnets and demonstrators. Exploiting the advantages of this method is today of critical importance for Nb$_{3}$Sn-based accelerator magnets, whose production requires the preservation of tight stress targets in the superconducting coils to limit the effects of the strain sensitivity and brittleness of the conductor. The present manuscript reports on the results of an experimental campaign focused on the optimization of the ‘bladders and keys’ assembly process in the MQXFB quadrupoles. These 7.2 m long magnets shall be among the first Nb$_{3}$Sn cryomagnets to be installed in a particle accelerator as a part of the High Luminosity upgrade of the LHC. One of the main practical implications of the bladders technique, especially important when applied to long magnets like MQXFB, is that to insert the loading keys, the opening of a certain clearance in the support structure is required. The procedure used so far for MQXF magnets involved an overstress in the coils during bladder inflation. The work presented here shows that such an overshoot can be eliminated thanks to additional bladders properly positioned in the structure. This optimized method was validated in a short model magnet and in a full-length mechanical model, becoming the new baseline for the series production at CERN. Furthermore, the results are supported by numerical predictions using finite element models.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

Analysis of the Mechanical Performance of the 4.2-m-Long MQXFA Magnets for the Hi-Lumi LHC Upgrade

Under the U.S. High Luminosity LHC Accelerator Upgrade Project (HL-LHC AUP), the 150 mm bore, high-field Nb 3 Sn low-{eta}_MQXFA quadrupole magnets are being fabricated, assembled and tested, in the context of the CERN Hi-Luminosity LHC (HL-LHC) upgrade. These magnets have 4.2 m magnetic length and 4.56 m long iron yoke. To date, eight MQXFA magnets have been tested. One of the magnets additionally underwent a successful endurance test with 40 triggered quenches, and two magnets did not perform as expected. This work summarizes for the first time the available strain gauge data from eight identical Nb 3 Sn MQXFA tested magnets, focusing on the endurance test, and on a possible cause of underperformance of the two magnets that did not pass the vertical test. Here we applied methods to prevent this from happening in future MQXFA magnets, which shown to be effective for last two tested magnets.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

The Challenges and Solutions of Meeting the Assembly Specifications for the 4.5 m Long MQXFA Magnets for the Hi-Luminosity LHC

The U.S. High-Luminosity LHC Accelerator Upgrade Project (HL-LHC AUP) has, in the recent years, developed assembly specifications for the 4.5 m long MQXFA magnets, which are 150 mm aperture high-field Nb 3 Sn low-β quadrupole magnets that are being built for the CERN Hi-Luminosity LHC (HL-LHC) upgrade. While the specifications were based on lessons learned from the LHC Accelerator Research Program (LARP) effort and the MQXFS and MQXFA prototype magnets, the experience gained from having both MQXFA07 and MQXFA08 magnets not meeting performance specifications during cold testing actually catalyzed a better understanding of the impact of the target assembly specifications and a subsequent refinement of the same. This paper summarizes a body of assembly data from the Pre-Series (MQXFA03-MQXFA07) and Series magnets (MQXFA08-MQXFA11) that have been built to date, and discusses the processes employed to successfully face the challenge of ensuring that the assembly specifications are met for the duration of the project.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Conceptual Design of a 20 T Hybrid Cos-Theta Dipole Superconducting Magnet for Future High-Energy Particle Accelerators

High energy physics research will need more and more powerful circular accelerators in the next decades. It is therefore desirable to have dipole magnets able to produce the largest possible magnetic field, in order to keep the machine diameter within a reasonable size. A 20 T dipole is considered a desired achievement since it would allow the construction of an 80 km machine, able to circulate 100 TeV proton beams. In order to reach 20 T, a hybrid Low-Temperature Superconductor (LTS) - High-Temperature Superconductor (HTS) magnet is needed, since LTS technology is presently limited to ~16 T for accelerator magnet applications. In this paper, we present the design of a 6 layers 20 T hybrid dipole magnet using Nb 3 Sn (LTS) and Bi2212 (HTS). Here we show that it is possible to achieve this magnetic field with accelerator field quality, with sufficient margin on a realistic conductor, keeping the stresses within safe limit, avoiding conductor degradation.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

A Novel Design for Improving the Control on the Stainless-Steel Vessel Welding Process for Superconducting Magnets

Stainless steel vessels see widespread use in superconducting magnets for particle accelerator applications. Their function varies in different magnet designs: they always provide the necessary liquid helium containment, but in some cases are also used to provide azimuthal prestress and can also be welded to the magnet end plate to provide additional longitudinal stiffness. A magnet designed with the bladder and key technology does not rely on the structural role of the vessel. They are structurally supported using azimuthally prestressed aluminum shells, and the longitudinal constraint by rods. In this case, the magnet designer would generally like to minimize the interaction between the magnet and the stainless-steel vessel and to minimize the coil stress variation due to the vessel. The stress state in the vessel and in the coil is a function of the circumferential interference, defined as the vessel azimuthal length minus the magnet circumference. The vessel and the magnet azimuthal length machining tolerances are relatively large resulting in significant stress variations in the superconducting coils. Here in this paper we introduce an interference-control shim, which can significantly limit the stress variation of the coils for a given variation of the interference. The effectiveness of the interference-control shim is evaluated numerically on the MQXF, the low-β quadrupole for the High Luminosity LHC.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

A Review of the Mechanical Properties of Materials Used in Nb 3 Sn Magnets for Particle Accelerators

Superconducting magnets experience significant thermo-mechanical loads throughout their life cycle. These are introduced by the electro-magnetic forces during powering, but also by the prestress applied in many magnet designs. Further to this, the large thermal excursion that components of different materials experience can generate significant internal forces. The loads are also experienced by the superconducting coils, whose critical current can decrease as a consequence of the applied strain. It is then crucial to predict the overall mechanical behavior and conservatively design a magnet, avoiding failure of the mechanical components and of the superconducting coils. Finite Element Analysis (FEA) is generally used to perform these tasks, but its results rely heavily on the material properties and models used. This is in particular true for the coil composite, which is simplified to allow reasonable model sizes in full magnet models. Here we present the state-of-art knowledge of the mechanical properties of the materials mostly used in superconducting magnet construction. We review elastic and plastic properties at room and cryogenic temperature, thermal contraction, and summarize the state-of-art failure criteria for these materials. Finally, the paper summarizes the present understanding of the mechanical behavior and limits of Nb3Sn coils. For the first time, an orthotropic failure criteria is proposed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

Computation of the Strain Induced Critical Current Reduction in the 16 T Nb 3 Sn Test Facility Dipole

A test facility dipole is being developed at LBNL, targeting a 16 T field in a 144 mm wide aperture. The magnet uses a block design, with two double-pancake coils. In order to minimize motion under the large Lorentz forces, the coils are preloaded against a thick aluminum shell and iron yoke using bladder and key technology. It is then crucial to verify that the performance of the magnet is not degraded due to strain induced on the Nb 3 Sn conductor during assembly, cool-down and powering. The critical current of extracted strands was measured in a varying background magnetic field and as a function of the applied longitudinal strain. Finite element analysis was used to extract the strain state inside the superconducting strands during magnet assembly and operation. This strain was then compared to the measurements to evaluate potential reversible and irreversible effects on the magnet performances. Here the results suggest that the magnet can reach 16 T with sufficient margin, with no irreversible degradation in the high field region.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

An Initial Look at the Magnetic Design of a 150 mm Aperture High-Temperature Superconducting Magnet With a Dipole Field of 8 to 10 T

High-temperature superconducting REBa 2 Cu 3 O 7-$x$ (rebco) conductors have the potential to generate a high magnetic field over a broad temperature range. The corresponding accelerator magnet technology, still in its infancy, can be attractive for future energy-frontier particle colliders such as a multi-TeV muon collider. To help develop the technology, we explore the requirements and potential characteristics of a rebco magnet, operating at 4.2 or 20 K, with a dipole field of 8-10 T in a clear aperture of 150 mm. We use the canted cos $\theta$ magnet configuration to reduce the electromagnetic stresses on the conductors. We present the resulting dipole fields, field gradients for combined-function cases, conductor stresses, magnet dimensions and conductor lengths. We also discuss the conductor performance that is required to achieve the target dipole field at 4.2 and 20 K. In conclusion, the information can provide useful input to the development of rebco magnet and conductor technology for collider-ring magnets in a muon collider.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

A Novel Design for Improving the Control on the Stainless-Steel Vessel Welding Process for Superconducting Magnets

Stainless steel vessels see widespread use in superconducting magnets for particle accelerator applications. Their function varies in different magnet designs: they always provide the necessary liquid helium containment, but in some cases are also used to provide azimuthal prestress and can also be welded to the magnet end plate to provide additional longitudinal stiffness. A magnet designed with the bladder and key technology does not rely on the structural role of the vessel. They are structurally supported using azimuthally prestressed aluminum shells, and the longitudinal constraint by rods. In this case, the magnet designer would generally like to minimize the interaction between the magnet and the stainless-steel vessel and to minimize the coil stress variation due to the vessel. The stress state in the vessel and in the coil is a function of the circumferential interference, defined as the vessel azimuthal length minus the magnet circumference. The vessel and the magnet azimuthal length machining tolerances are relatively large resulting in significant stress variations in the superconducting coils. In this paper we introduce an interference control shim, which can significantly limit the stress variation of the coils for a given variation of the interference. The effectiveness of the interference-control shim is evaluated numerically on the MQXF, the low-β quadrupole for the High Luminosity LHC.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

Analysis of MQXFA07 Test Non-Conformity

MQXFA07 did not meet acceptance requirement during vertical test. This report presents the analysis of MQXFA07 components related to the limited test performance, and the damage mechanism as it was understood by the MQXFA team.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

US HL-LHC Accelerator Upgrade Project: MQXFA11 shipping incident report

The truck transporting the MQXFA11 magnet from LBNL to BNL was involved in an accident on 7/20/22. It was rear ended by another truck. Drivers were not injured. The main hit took place on the right back corner. The truck with the MQXFA11 magnet was towed to a tow yard in Rockdale, IL (~50 min drive from Fermilab). Subsequently, it was moved on another truck and moved to Fermilab. Fermilab employees added 3 accelerometers on the crate before it was moved on the new truck and attended all loading/unloading operations at the tow yard and at FNAL. The magnet arrived at FNAL on July 28 th . Upon arrival a visual inspection was performed. Accelerometers were removed and shock data were analyzed. Electrical checkout and a metrology survey were carried out. Strain data were also collected from the fiber optics installed on two coils and compared with data obtained before shipment. This report presents a summary of results. More pictures and details can be found at: https://indico.fnal.gov/event/55698/

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

MQXFA11 shipping incident report

The truck transporting the MQXFA11 magnet from LBNL to BNL was involved in an accident on 7/20/22. It was rear ended by another truck. The magnet arrived at FNAL on July 28th. Upon arrival a visual inspection was performed. Accelerometers were removed and shock data were analyzed. Electrical checkout and a metrology survey were carried out. Strain data were also collected from the fiber optics installed on two coils and compared with data obtained before shipment. This report presents a summary of results.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

Fiber-optic diagnostic system for future accelerator magnets

The next generation high energy physics accelerators will require magnetic fields at ~20 T. HTS coils will be an essential component of future accelerator magnets and several efforts are currently dedicated on designing 20 T HTS- LTS hybrid magnets. Among the existing challenges, there is the lack of a robust quench detection system for hybrid magnet technology. Another big challenge is represented by the high number of training quenches required by Nb3Sn magnets to reach performance level. In this framework it is important to find a tool that allow local real-time monitoring of magnet strain and temperature. In this paper, we propose the use of fiber optics sensors for diagnostic and quench detection in future accelerator superconducting magnets. Discrete and distributed fiber optic sensors have demonstrated to be a promising tool. The goal is to instrument hundreds of accelerator superconducting magnets and to move beyond the proof-of-concept level. Significant developments are still needed. Here, we are going to present the most recent results and discuss the most urgent technical developments in order to make those sensors a robust and reliable diagnostic tool for accelerator superconducting magnets over the next 10 year. We foresee that discrete fiber sensors will be a stable diagnostic probe for superconducting magnets over the next 3 to 5 years. More R&D work will be necessary for distributed fibers. The most urgent needs are the increase of sample rate and sensitivity. Close collaboration with vendors will be necessary to improve mechanical properties and fabrication processes in order to produce hundreds of meters of fiber and instrument a large number of accelerator superconducting magnets. Those R&D efforts will last up to 10 years with a founding level that spans between 5-10 M$.

43 PARTICLE ACCELERATORS↗