manufacturing process, validation and factory test ess rfq cdr2 2015 12 08-09 bruno pottin
TRANSCRIPT
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
| PAGE 3
Bruno POTTIN
SECTION MANUFACTURING
One RFQ section manufacturing’s steps process
| PAGE 4
1 Copper + HIP
2 Ancillaries
3 Section manufacturing
4Brazing process
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
COPPER AND HIP
| PAGE 5
Bruno POTTIN
COPPER AND HIP
One RFQ section manufacturing’s steps process
| PAGE 6
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
| PAGE 7
Example of an porosity in IPHIcopper on a brazing plan
Bruno POTTIN
COPPER PROVIDING PROCESS
| PAGE 8
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
| PAGE 9
Assembly by brazingHIP treatment
3 holes : 1,2 and 3 mm diameter
Ø 2 Ø 3Ø 1
Bruno POTTIN
HIP TREATMENT MOCK-UP
| PAGE 10
Before
After
After HIP, we have :
- Holes disappeared
Metallographic study :
- Grain size increase- Low hardness
Bruno POTTIN
HIP EQUIPMENT
| PAGE 11
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)
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
ANCILLARIES
| PAGE 12
Bruno POTTIN
SECTION MANUFACTURING
One RFQ section manufacturing’s steps process
| PAGE 13
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
| PAGE 14
IPHI ESS
IPHI
IPHI
Bruno POTTIN
ANCILLARIES MANUFACTURING
Ancillaries manufacturing’s steps process
| PAGE 15
Leak test
Tridimmeasurement
Bruno POTTIN
ANCILLARIES PROCUREMENT : TEST CAVITY
| PAGE 16
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
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
SECTION MACHINING
| PAGE 17
Bruno POTTIN
IPHI’s project : 4 copper parts per section chosen for ESS
MAIN TECHNOLOGICAL CHOICES
| PAGE 18
Machining
Assembly
Brazing copper
parts and ancillaries in vertical position in
1 step
Bruno POTTIN
SECTION MANUFACTURING
One RFQ section manufacturing’s steps process
| PAGE 19
Bruno POTTIN
SECTION MANUFACTURING
Manufacturer and process validation
| PAGE 20
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
SECTION MANUFACTURING
| PAGE 21
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
One RFQ section manufacturing’s steps process
| PAGE 22
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
SECTION MANUFACTURING
| PAGE 23
TriDim
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
BRAZING PROCESS
| PAGE 24
Bruno POTTIN
SECTION MANUFACTURING
One RFQ section manufacturing’s steps process
| PAGE 25
2 different brazing
processes
Bruno POTTIN
2 BRAZING PROCESSES
| PAGE 26
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
SECTION MANUFACTURING
One RFQ section manufacturing’s steps process
| PAGE 27
• Tridim measurement to check the section• RF measurement• Brazing• Leak test• RF measurement• Tridim measurement
Ancillaries adapted
for brazing
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
COUPLERS
| PAGE 28
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
MAIN TECHNOLOGICAL CHOICES
| PAGE 29
COUPLER MANUFACTURING
| PAGE 30Bruno POTTIN
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
| PAGE 31
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
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
TUNERS
| PAGE 32
Bruno POTTIN
MAIN TECHNOLOGICAL CHOICES
| PAGE 33
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
| PAGE 34
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
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
FACTORY ACCEPTANCE TEST
| PAGE 35
Bruno POTTIN
MANUFACTURING TRACKING
| PAGE 36
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
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
THANK YOU
| PAGE 39
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
| PAGE 40