lcls cavity bpm production status
DESCRIPTION
LCLS Cavity BPM Production Status. M1-Tool Works BPM Production. M1 awarded contract for machining bodies and transitions for 20 sets of parts First Production BPM mechanical measured and Pre-lim cold test look very good. First production unit. Cavity Production Status. - PowerPoint PPT PresentationTRANSCRIPT
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
M1-Tool Works BPM Production
M1 awarded contract for machining bodies and transitions for 20 sets of partsFirst Production BPM mechanical measured and Pre-lim cold test look very good
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Cavity Production Status
M1-Tool Works to deliver 11 units 1/22/08 presently on schedule
Exercised the option for additional 20 units order from M1-Tool 1/08
Parts are on time and in spec so far
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Cold Test Set-Up for Pre-Braze test
New production test fixtures for pre-braze testing
First production unit looks good and parts are at Altair waiting to be brazed
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Cavity BPM Cold Test Data
Serial # Dipole Freq. (GHz)
DipoleLoaded Q
MonopoleFreq. (GHz)
MonopoleLoaded Q
Design Goal 11.384 3550 11.384 3695
Production # 010
11.384Pre-Braze
2987Pre-Braze
11.379Pre-Braze
2000Pre-Braze
Prototype # 001
11.374 3250 11.382 3372
Prototype # 002
11.376 3500 11.383 3436
Prototype # 003
11.377 3371 11.400 3200
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
First Production Unit Shipped to
Serial # 010 shipped to Altair for brazing 12/21/07
Unit pending complete braze due to window problem
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Production Risks (Presented at FAC 10/30/07)
New End Cap design
New tuning scheme
Window plating problem
Unexpected integration problem
Unexpected vendor problem
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
The Window Braze Yield Problem
Problem brazing the window into the transition has caused delivery delay
Convergence and down-select of possible solutions pending
Concentration of effort critical
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Understanding the Problem
HistoryWhy were ALL the soldered units vacuum
tight?
15 for 15Why did the units built for the 3-BPM work
so well compared to present results
6 small leaks, 9 good NO CRACKING
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
BPM Window Braze History
Prototype cold test unit, ITS test unit and 3-BPM test unit S/N 01 soldered Sn-Ag-Cu Vacuum tight2 test brazes Georo Vacuum tight3-BPM S/N R/0 first Georo braze Vacuum tight
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Georo Test Braze before 3-BPM units
First test brazes clean and vacuum tight 5/12/07
No risk at this time so units for 3-BPM testing would be processed with Georo braze material
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
First Problem Window
3-BPM test Ser # 03 Georo Braze Results:
2 out of 5 leaked and the 2 that leaked had “glossy” Ni plating3-BPM test Ser # 02 Georo Braze Results:
4 out of 5 leaked and the 4 that leaked had “glossy” Ni plating
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Corrective Action from 3-BPM Window Failures
Start R&D program to identify problem with bright Ni
CPI suggested using gold plating of first trials
First sample failed 10/07 because of apparent cracks and “spattering”
Possible cause was cool down too rapid
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Window Problem Status 01/21/08
Moly retaining ring and retaining outer blockLower temperature braze (Orotin) with induction heating re-workCPI supplies transition with window installedKovar frame Two piece transitionBolt on windowCoax adapter
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Cavity BPM Production Recovery Options without changing the design
Option 1 Lower temperature braze (Orotin) and Induction heating re-work plan
Option 2 Work with CPI for a turn-key solution providing completed transition
Option 3 Braze window into a frame (Kovar) with similar expansion coef and weld into transition
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Braze with existing/modified parts
PROs
Lowest risk option
Fastest recovery
Re-work plan possible
Lowest cost impact
No risk to qualified BPM system design
CONs
Yield not satisfactory
Re-work plan needs work
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Induction Heating
Working with Ameritherm to re-work window after failed braze
Braze can be re-worked by applying additional paste or powder to joint
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Receiver Electronics Production Status
All parts on order
Test fixtures developed
Parts to start arriving 2/08
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Production Status
M1-tool Works delivered first unit 11/07 on time and in spec
First unit has been QA tested and cold tested with very good results
First unit is at Altair being Brazed less waveguide transitions
ANL to supply Altair with first set of modified window/transitions
Addition 11 BPMs in process at ANL
Bob Lill
LCLS week meeting [email protected]
January 22-24, 2008
Production Milestones
Production of 1 BPMs for LTU 02/08
Production of 11 BPMs for undulator/LTU 03/08
Production of 12 BPMs for undulator 04/08
Production of 12 BPMs for undulator 05/08
Spares 4 BPMs 06/08
40 sets of Electronics 08/08