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DOE OSTI2025

QXFA 167 Coil Fabrication Report

QXFA is a cosine theta coil used in the MQXFA, a Nb3Sn superconducting accelerator quadrupole magnet to be installed in the High-Luminosity LHC Interaction Regions. A series of MQXFA magnets is fabricated and tested by the US High-Luminosity LHC Accelerator Upgrade Project (AUP). This report details the fabrication process of the QXFA coil (QXFA 167) using Wind-and-React method, conducted from February 6 to March 20, 2025. The content covers coil winding, curing, and reaction, based on the travelers of FNAL as well as the observations and records by the author. The coil fabrication processes following heat reaction, including the impregnation process, are not covered in this report, as they were carried out after March 20.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Lessons from Testing the First Three US HL-LHC Cryo-Assemblies at FNAL

The US High-Luminosity LHC Accelerator Upgrade Project (AUP) collaborates with CERN to deliver 10 cryo-assemblies for the High-Luminosity LHC upgrade at CERN. Those comprise the Q1/Q3 quadrupole optical elements in the accelerator and are based on Nb3Sn technology, for the first time in a large particle accelerator. So far three cryo-assemblies were tested at the Fermilab’s horizontal magnet test facility, specifically redesigned to serve those needs. This work gives an overview of the facility and its necessary evolution as the campaign progressed; main results and observations from the cryo-assembly tests are presented and discussed in the context of overall performance and expectations toward the completion of efforts. Lessons learned after multiple cryo-assembly tests by the same team are critical to ensure continuous success of the whole enterprise – those are openly shared.

Stoynev, Stoyan [Fermilab]↗

DOE OSTI2025

A dedicated mirror-magnet experiment to study quench characteristics and dependencies in $Nb_{3}Sn$ coils and explore improvements of diagnostics capabilities

A single Nb3Sn short quadrupole coil in a mirror-magnet configuration was employed to investigate a wide range of phenomena and to serve as test-bed for diagnostics developments. A configurable array of spot-heaters was installed on the inner coil surface for control of induced quench conditions. Several different quench antenna arrays were positioned along the coil inner surface, and included significant sensor overlap for assessment of their relative efficiency and operation. Multiple acoustic sensors were placed on the pole and at coil ends. Optical fibers in grid configurations were put in different places on the coil and magnet for strain assessment, along with standard resistive strain gauges. Current spikes in the magnet circuit were monitored. This plethora of instrumentation aimed to support investigations on induced and spontaneous quenches, among other goals, and was supplemented by standard voltage-tap-based measurements. Voltage tap data of induced quenches from various spot-heater configurations was investigated for similarities to voltage development in spontaneous quenches. Quench antennas provided insights about current redistribution in the quenching coil and coil splices. The Quench Current-boosting Device was applied and the effect on coil training examined. This paper describes motivations behind the research, the overall test setup and main results.

Stoynev, Stoyan [Fermilab]↗

DOE OSTI2025

Test results of the LQXFA/B02 and LQXFA/B03 cryo-assemblies for the High Luminosity LHC upgrade

The US High-Luminosity LHC Accelerator Upgrade Project (AUP) is responsible for delivering cryo-assemblies for the Q1/Q3 quadrupole optical components of the High Luminosity LHC upgrade at CERN. Total of 10 cryo-assemblies containing two Nb3Sn quadrupole magnets per cold mass will be delivered within this program. After the successful test of the first pre-series cryo-assembly in 2023, two more cryo-assemblies were tested at Fermilab’s horizontal test facility. Production overview and the test results of the LQXFA/B02 and LQXFA/B03 cryo-assemblies are summarized in this paper. After the first test, to increase the capability of the horizontal test facility, various improvements have been made. These improvements are also described in this paper.

Chlachidze, Guram [Fermilab]↗

DOE OSTI2026

Optimization of Nb 3 Sn sputtering on SRF structures

Superconducting radiofrequency (SRF) cavities are the key technology to compact, high-efficiency, and cost-effective CW SRF accelerators. Further improvements in the efficiency can be realized by using novel materials such as Nb 3 Sn coated on the inner surface of SRF cavities. The Nb 3 Sn coatings enable cavity operation at 4 K, where the Nb 3 Sn coated cavities are already very efficient and have high intrinsic quality factors. Advances in Nb3Sn coatings on the inner surface of SRF cavities showed the potential for this material to significantly cut the capital and operating costs of SRF accelerators. Several approaches have been and are being investigated for coating SRF cavities with Nb 3 Sn. Magnetron sputtering is a versatile technique in that it has been shown to produce Nb 3 Sn films on flat Nb target in a single phase and a precisely controlled thickness, low defect levels, and a favorable morphology. Deposition of Nb 3 Sn films on SRF cavities have also shown promising RF superconducting properties. However, sputter coating of Nb 3 Sn on SRF cavities requires further development to be used in accelerators.

43 PARTICLE ACCELERATORS↗

NASA NTRS1962

Evaluations of Space Shielding

A general method of evaluating the efficiency of space vehicle shielding is developed and used to compare various active and passive systems for protection against ionizing radiation. Available permanent magnets are found useless for active shielding, and combined active-passive systems in general are determined to be inefficient. On the other hand, evaluations show that active electrostatic shielding may have possibilities for weight savings if electrical conditions (presently unknown) are favorable therefor in space. Further, a positive potential improvement is calculated for an active shielding system which utilizes superconducting Nb3Sn to provide a confined magnetic flux to deflect incident charged particles; this potential points toward substantial reductions in shield weight for the protection of large vehicles from highly energetic particles. Recommendations are made for further research, particularly for flight experiments to measure directionality of solar flare protons.

SHIELDING↗

NASA NTRS1972

New twisted intermetallic compound superconductor: A concept

Method for processing Nb3Sn and other intermetallic compound superconductors produces a twisted, stabilized wire or tube which can be used to wind electromagnetics, armatures, rotors, and field windings for motors and generators as well as other magnetic devices.

Coles, W. D.↗

NASA NTRS1973

The use of superconductivity in magnetic balance design

The magnetic field and field gradient requirements for magnetic suspension in a Mach 3, 6-in. diameter wind tunnel are stated, along with the power requirements for gradient coil pairs wound of copper operating at room temperature and aluminum cooled to 20 K. The power dissipated is large enough that the use of superconductivity in the coil design becomes an attractive alternative. The problems of stability and ac losses are outlined along with the properties of stabilized superconductors. A brief review of a simplified version of the critical state model of C. P. Bean is presented, and the problems involved in calculations of the ac losses in superconducting coils are outlined. A summary of ac loss data taken on pancake coils wound of commercially available Nb3Sn partially stabilized tape is presented and shown as leading to the U.Va. gradient coil design. The actual coil performance is compared with predictions based on the BNL results. Finally, some remarks are presented concerning scaling of the ac losses to larger magnetic suspension systems as well as prospects for improved performance using newer multifilament superconductors.

Moss, F. E.↗

NASA NTRS1973

NASA superconducting magnetic mirror facility

The design details and initial test results of a superconducting magnetic mirror facility that has been constructed at NASA Lewis Research Center for use in thermonuclear research are summarized. The magnet system consists of four solenoidal coils which are individually rated at 5.0 T. Each coll is composed of an inner, middle, and outer winding. The inner winding is wound of stabilized Nb3Sn superconducting ribbon, and the middle and outer windings are wound of stabilized Nb-Ti superconducting wire. When arranged in the mirror geometry, the four coils will produce 8.7 T at the mirrors and a 1.8 mirror ratio. The magnet has a 41-cm diameter clear bore which is open to atmosphere. Distance between the mirrors is 111 cm. Presently there are only three magnets in the facility; the fourth magnet is being rebuilt.

Reinmann, J. J.↗

NASA NTRS1973

NASA superconducting magnetic mirror facility

This report summarizes the design details and initial test results of a superconducting magnetic mirror facility that has been constructed at NASA Lewis Research Center for use in thermonuclear research. The magnet system consists of four solenoidal coils which are individually rated at 5.0 T. Each coil is composed of an inner, middle, and outer winding. The inner winding is wound of stabilized Nb3SN superconducting ribbon, and the middle and outer windings are wound of stabilized Nb-Ti superconducting wire. When arranged in the mirror geometry, the four coils will produce 8.7 T at the mirrors and a 1.8 mirror ratio. The magnet has a 41-cm diameter clear bore which is open to atmosphere. Distance between the mirrors is 111 cm. Presently there are only three magnets in the facility; the fourth magnet is being rebuilt.

Reinmann, J. J.↗

NASA NTRS1978

Electronic instability and change of crystalline phase in compounds of the V3Si type at low temperature

In V3Si, the V atoms form an array of dense linear chains; a tight-binding approximation in one dimension was used to describe the d electrons. The electronic energy calculated by this method was reduced when the lattice is deformed. This lead to a band type of the Jahn Teller effect, which may explain the cubic to tetragonal transition which was observed at low temperatures. The theory can be extended to other superconductors of the V3X type when X=Ga, Ge, Sn, etcetera, or NB3SN.

Labbe, J.↗

NASA NTRS2003

A Compact, Continuous Adiabatic Demagnetization Refrigerator with High Heat Sink Temperature

In the continuous adiabatic demagnetization refrigerator (ADR), the existence of a constant temperature stage attached to the load breaks the link between the requirements of the load (usually a detector array) and the operation of the ADR. This allows the ADR to be cycled much faster, which yields more than an order of magnitude improvement in cooling power density over single-shot ADRs. Recent effort has focused on developing compact, efficient higher temperature stages. An important part of this work has been the development of passive gas-gap heat switches that transition (from conductive to insulating) at temperatures around 1 K and 4 K without the use of an actively heated getter. We have found that by carefully adjusting available surface area and the number of He-3 monolayers, gas-gap switches can be made to operate passively. Passive operation greatly reduces switching time and eliminates an important parasitic heat load. The current four stage ADR provides 6 micro W of cooling at 50 mK (21 micro W at 100 mK) and weighs less than 8 kg. It operates from a 4.2 K heat sink, which can be provided by an unpumped He bath or many commercially available mechanical cryocoolers. Reduction in critical current with temperature in our fourth stage NbTi magnet presently limits the maximum temperature of our system to approx. 5 K. We are developing compact, low-current Nb3Sn magnets that will raise the maximum heat sink temperature to over 10 K.

Shirron, P. J.↗

NASA NTRS2003

A 10 Kelvin Magnet for Space-Flight ADRs

Future NASA missions will include detectors cooled by adiabatic demagnetization refrigerators (ADRs) coupled with mechanical cryocoolers. A lightweight, low-current 10 Kelvin magnet would allow the interface between these devices to be at temperatures as high as 10 Kelvin, adding flexibility to the instrument design. We report on the testing of a standard-technology Nb3Sn magnet and the development of a lightweight, low-current 10 Kelvin magnet. We also discuss the outlook for flying a 10 Kelvin magnet as part of an ADR system.

Tuttle, James↗

NASA NTRS2003

Continuous Cooling from 10 K to 4 K Using a Toroidal ADR

Future large infrared space telescopes will require cooling to 4K to achieve background limited performance for submillimeter wavelengths. These observatories will require lifetimes of many years and will have relatively large cooling requirements making stored helium dewars impractical. We have designed and are building an adiabatic demagnetization refrigerator (ADR) for use in cooling relatively large loads (10- 100 mW) at 4K and rejecting that heat to a cryocooler operating at 1 OK. Cryocoolers below 1 OK have poor thermodynamic efficiency and ADRs can operate in this temperature range with an efficiency of 75% of Carnot or better. Overall, this can save as much as 2/3 of the input power required to operate a 4K cryocooler. The ADR magnet consists of 8 short coils wired in series and arranged in a toroid to provide self shielding of its magnetic field. This will save mass (about 30% of the mass or about 1.5 kg in our small version, higher percentages in higher cooling power, larger versions) that would have been used for passive or active shields in an ordinary solenoid. The toroid has a 100 mm outer diameter and will produce an approximately 3T average field. In the initial demonstration model the toroid coils will be wound with ordinary NbTi wire and operated at 4K. A second version will then use Nb3Sn wire to provide complete 10K operation. As a refrigerant for this temperature range we will use either GdLiF4 or GdF3 crystals, pending tests of these crystals' cooling capacity per field and thermal conductance. Preliminary indications are that these materials are superior to GGG. We will use gas gap heat switches to alternately connect the toroid to the cold load and the warm heat sink. A small continuous stage will maintain the cold end at 4K while the main toroid is recycled.

DiPirro, Michael J.↗

NASA NTRS2019

Development of a Flight-Worthy 10 to 4 K Continuous Adiabatic Demagnetization Refrigerator

The cryogenics and fluids branch at NASA's Goddard Space Flight Center is currently developing a high-efficiency, vibration-free, flight-worthy Continuous Adiabatic Demagnetization Refrigerator (CADR) that consist of two modular units: one that lifts ~6 microW at 50 mK while rejecting its heat to a 4 K thermal sink, and another unit that provides a constant 4 K cooling stage while rejecting its heat to a thermal sink at 10 K. The two units are linked together via a 4 K common platform. This paper discusses the status report on the thermodynamic performance of the 4 -10 K ADR. This ADR utilizes an Nb3Sn superconducting magnet and Gadolinium Gallium Garnet (GGG) as its refrigerant. Results show that an idealized cycle, one where its hold time at 4 K is equal to the recycle time, can lift 13 mW at 4 K with a hold time of 132 seconds.

CADR↗

DOE OSTI2021

High-current conduction cooled superconducting radio-frequency cryomodule

A high-current, compact, conduction cooled superconducting radio-frequency cryomodule for particle accelerators. The cryomodule will accelerate an electron beam of average current up to 1 ampere in continuous wave (CW) mode or at high duty factor. The cryomodule consists of a single-cell superconducting radio-frequency cavity made of high-purity niobium, with an inner coating of Nb3Sn and an outer coating of pure copper. Conduction cooling is achieved by using multiple closed-cycle refrigerators. Power is fed into the cavity by two coaxial couplers. Damping of the high-order modes is achieved by a warm beam-pipe ferrite damper.

Ciovati, Gianluigi↗

DOE OSTI2022

White Paper on High Temperature Superconducting Bi-2212 Magnets for Energy Frontier Circular Colliders

As the only high-temperature superconducting (HTS) material available as an isotropic, twisted, multifilamentary round wire, Bi-2212 is very promising for expanding the high-field superconducting accelerator magnet toolbox beyond the round-wire, isotropic Nb-Ti and Nb3Sn conductors used by HEP so far. In this paper, we describe the important roles that Bi-2212 might play for future high energy circular colliders including both high energy proton and muon colliders. We describe its present technology status (conductor development, magnet design concepts, prototype magnet status) and then provide a ten-year plan for >15 T accelerator magnets and >25 T solenoid magnets within an integrated strategy to engage industry and the entire US and international scientific enterprise interested in HTS magnet applications.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

Critical problems of energy frontier Muon Colliders: optics, magnets and radiation

This White Paper brings together our previous studies on a Muon Collider (MC) and presents a design concept of the 6 TeV MC optics, the superconducting (SC) magnets, and a preliminary analysis of the protection system to reduce magnet radiation loads as well as particle backgrounds in the detector. The SC magnets and detector protection considerations impose strict limitations on the lattice choice, hence the design of the collider optics, magnets and Machine Detector Interface (MDI) are closely intertwined. As a first approximation we use the Interaction Region (IR) design with beta-star=3 mm, whereas for the arcs we re-scale the arc cell design of the 3 TeV MC. Traditional cos-theta coil geometry and Nb3Sn superconductor were used to provide field maps for the analysis and optimization of the arc lattice and IR design, as well as for studies of beam dynamics and magnet protection against radiation. The stress management in the coil will be needed to avoid large degradation or even damage of the brittle SC coils. In the assumed IR designs, the dipoles close to the Interaction Point (IP) and tungsten masks in each IR (to protect magnets) help reducing background particle fluxes in the detector by a substantial factor. The tungsten nozzles in the 6 to 600 cm region from the IP, assisted by the detector solenoid field, trap most of the decay electrons created close to the IP as well as most of the incoherent electron-positron pairs generated in the IP. With sophisticated tungsten, iron, concrete and borated polyethylene shielding in the MDI region, the total reduction of background loads by more than three orders of magnitude can be achieved.

43 PARTICLE ACCELERATORS↗