Transcript Undulator Vacuum Chambers and System

Undulator Vacuum System
Dean R. Walters
Soon-Hong Lee, James Bailey, James Morgan,
Dana Capatina, Scott Doran, ANL
Apr. 16, 2007
Undulator Breakout
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Dean R. Walters
[email protected]
Undulator Vacuum System
Beam Finder Wire
Undulator Vacuum Chamber
Prototypes
Production
Vacuum System
String Test Results
Apr. 16, 2007
Undulator Breakout
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Dean R. Walters
[email protected]
BFW Production Plan
Wire Card
Fixtures
Chamber
Hardware
Weldment
Machined Parts
Catalog Items
Assemble, Weldment/Chamber/Card
Leak check and bake out
Procured
Components
Work
performed
at ANL
Install Machined Parts/Catalog Items/
Hardware on the Assembly
Perform Nominal Alignment Procedure
and Operational Tests
Package and ship to SLAC
Apr. 16, 2007
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Dean R. Walters
[email protected]
BFW Status of Production
Weldment, Machined Parts, Chamber, Catalog
Items and all Hardware---Design and
Procurement Documents are complete and are in
the procurement process
Wire Card is currently under final design.
Fixture designs are 90% complete.
Alignment and Assembly Procedures are 50%
complete.
Apr. 16, 2007
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Dean R. Walters
[email protected]
BFW Production Schedule
What is the current Schedule
Apr. 16, 2007
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Dean R. Walters
[email protected]
Prototype Vacuum Chambers
NW 50 Flange -Clamp Type
(316L SST)
Compound screws
(Brass Screws & SST )
Vacuum Chamber
Prototype A
Chamber Strong-back
(20Cb-3)
Top & Bottom
Strips (316LN)
End Cap
(20Cb-3)
Top & Bottom
Strips (20Cb-3)
End Cap
(20Cb-3)
Prototype B
Chamber Strong-back
(316 SST)
Apr. 16, 2007
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Dean R. Walters
[email protected]
Status of Prototype Efforts
42 inch Prototype
Completed fabrication
Constructed Laser Welding tooling for 42” prototype
Leaks repaired with Ag braze
First coating
Chamber cut up for visual examination
Proto B (12 ft proto)
Completed all Fabrication’s steps
Constructed Laser Welding tooling for 12 ft prototypes
Repaired leaks with Ag brazing and Sn-Ag-Cu soldering
Completed both Bakes & was coated
Unit completed vacuum performance measurement
Installed into SUT for straightness measurement
Chamber used in String Test
Proto A (12 ft proto)
Completed all fabrications steps
Repaired leaks by Laser Welding
Completed both Bakes and was coated
Unit completed vacuum performance measurement
Chamber used in String Test
Chamber has been machined into parts for further examination
Coating fixture in place and in use.
Pivoting fixture installed
All safety inspections complete
End stations complete
Apr. 16, 2007
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Dean R. Walters
[email protected]
Production Chamber Permeability
(full length Prototype A)
As-received
Alloy 20
1.009 ~ 1.010
(0.75” thick)
After fabrication,
permeability  1.013
[spec: 1.02]
Apr. 16, 2007
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Dean R. Walters
[email protected]
Laser Seam Welding - 12 Foot Prototype
Transferring Fixturing from Strong Back
Weld Configuration to End Cap Weld
Fixturing for Strong Back Weld
Fixturing for End Cap Weld
Apr. 16, 2007
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Dean R. Walters
[email protected]
Prototype A Laser Welding
Drawing shows the location of the leaks
The majority of the leaks occur at the weld overlaps
The chamber was welded in three sections
The chamber was sent back to the vendor of weld repair
The chamber was baked after leak repair and none have re-opened
Apr. 16, 2007
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Dean R. Walters
[email protected]
Final Machining Method
1” wide cut
by 1-0.100”
deep
1” wide cut by
2-0.030” and
4-0.010” deep
0.020” final wall thickness
Side Wall
Strong
Back
Vacuum
Chamber
Xsection
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End Cap
11
Dean R. Walters
[email protected]
12 foot Coating Set-up
Apr. 16, 2007
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Dean R. Walters
[email protected]
12 Foot Test – 2/2/2007
Sample
Location
Sample
Location
Apr. 16, 2007
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Dean R. Walters
[email protected]
Coating Results
Test were performed by inserting silicon samples into 13 mm ID SST spool.
Each test had four samples down the length. In most cases the samples were
measured in more than one location
Uniformity down the length
In three different tests over the 12 foot length
Test #1: Average thickness of 98 nm with uniformity of 10%
Test #2: Average thickness of 325 nm with uniformity of 4.3%
Test #3: Average thickness of 210 nm with uniformity of 12%
Results of surface finish
Test #1 surface increased roughness by 1 nm
Test #2 surface roughness was unchanged by the coating
Test #3 surface increased roughness by 2 nm
Plans for further measurements
Apr. 16, 2007
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Dean R. Walters
[email protected]
Coating of Proto A
Coating of Proto B
Performed on 9 Feb. 2007
Repeated on 13 Feb. 2007
Performed on 16 Feb. 2007
Apr. 16, 2007
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Dean R. Walters
[email protected]
Baking the Prototypes
Measurements of Vacuum Performance
Prototype B
(Outgassing Rate Spec: 2x10-12 Torr-Lit/sec/cm2)
Prototype A
Proto B
Base Pressure : 5.9x10-9 / 1.1x10-9
Outgassing Rate : avg. of 6x10-13 Torr-Lit/sec/cm2
Proto A
Base Pressure : 2.2x10-9 / 2.5x10-9
Outgassing Rate : avg. of 3x10-13 Torr-Lit/sec/cm2
Baking of Prototypes A and B
Proto B
1st bake (before coating) at 200 deg C
2nd bake (after coating) at 150 deg C
Proto A
1st bake (before coating) at 150 deg C
2nd bake (after coating) at 150 deg C
Apr. 16, 2007
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Dean R. Walters
[email protected]
Chamber Alignment/Survey Results
SUT Mockup Chamber
Prototype B Chamber
Vertical Adjustment Screws
(14)
Results showed the vertical centerline of vacuum
chamber can be within tolerance of ± 200 µm
Apr. 16, 2007
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Dean R. Walters
[email protected]
Production Vacuum Chamber Ass’y
Vacuum Chamber Assembly
X-Adjustor
Z-Adjustor
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Support Assembly
Dean R. Walters
[email protected]
Fabrication Processes
Apr. 16, 2007
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Dean R. Walters
[email protected]
Preparations for Production
Advanced Procurement Plan written and in the process of being signed.
Support Assembly
SOW completed
Purchase requisition in system
Chamber Material
Alloy 20 for first 4 units in house
Alloy 20 for next 8 units have a requisiton placed in the ANL purchasing
Purchase requisition for next 25 in system
Side Wall
Vendor making first article
Draft SOW is complete
Strongback
SOW is complete and being signed
Requisition is in the ANL system
End Cap
SOW is complete and being signed
Requisition is in the ANL system
All drawings for the chamber and the support have been completed and released.
Minor updates have been incorporated.
(4) Full sheets of polished 316LN have been bought, samples have had the surface finish measured and accepted for
use.
Strips have been made from this material and used in Prototype A.
The (2) sheets are sufficient for the entire production run.
A test run is under way to water jet cut strips and to machine the edges, if this is satisfactory then this vendor will produce the rest of the
parts.
Material for the first (4) strongbacks have been bought and are ready to be shipped to machining vendors.
Samples of material have already been submitted for permeability measurement and have been accepted.
Material for the first (8) end caps have been bought and are ready to be shipped to machining vendor.
Tooling has been made, and used, for: machining the strongback, laser welding, and final machining.
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Dean R. Walters
[email protected]
Chamber Schedule
Apr. 16, 2007
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Dean R. Walters
[email protected]
String Test Results
Apr. 16, 2007
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Dean R. Walters
[email protected]
Concerns & Open Issues
Have developed Laser Welding and built tooling with vendor in Iowa.
Need qualified strongback machining vendors
Will need 2 for production
Need to locate qualified Final Machining vendor
All Final Machining of prototypes were performed by ANL Central Shops.
Continue coating development now that contact is reestablished with
thin film consultant.
Cost of Nickel is raising, pricing of Alloy 20 is subject to increase.
Attempt of offset that by placing order now for future delivery
Permeability of Alloy 20 is of concern, since the material used in Proto A
is measurably lower in relative permeability than first antisapated further
measurements will be performed. Proto A has been cut up and a
section will be used for measuring permeability in an ANL undulator.
Since performing a vacuum pumpdown string test, Proto A has been cut
apart to inspect the internal surfaces.
Apr. 16, 2007
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Dean R. Walters
[email protected]
Conclusions
Two full sized prototypes have been built.
All planned fabrication steps have been performed.
Seam Welds were performed by Laser Welding.
Even though leaks were found, they have been repaired.
The vendor is organizing further work to address them.
Construction of the 12 foot fixture and initial development of
the AC Diode Sputtering process has lead to Aluminum
coatings applied to both prototypes.
The chambers have been baked and their measured
outgassing rate is lower than the specification
Many preparations for production are in-process or in place.
Apr. 16, 2007
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Dean R. Walters
[email protected]