LHC Accelerator Research Program Research Articles

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 <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sub> 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.

Progress in the Development of the Nb3Sn MQXFB Quadrupole for the HiLumi Upgrade of the LHC

The high-luminosity upgrade of the Large Hadron Collider (HL-LHC) requires new high field and large-aperture quadrupole magnets for the low-beta inner triplets (MQXF). With a nominal operating gradient of 132.2 T/m in a 150 mm aperture and a conductor peak field of 11.3 T, the new quadrupole magnets are based on Nb <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sub> Sn superconducting technology. After a series of short models constructed in close collaboration by LARP (LHC Accelerator Research Program) and CERN, the development program is entering in the series production phase with CERN on one side and the US Accelerator Upgrade Project (US-AUP) on the other side assembling and testing full-length magnets. This paper describes the status of the development activities at CERN, in particular on the cold powering test of the first MQFXB prototype and on the construction of the second full scale prototype. Critical operations such as reaction heat treatment, coil impregnation and magnet assembly are discussed. Finally, the plan towards the series production is described.

Fracture Failure Analysis for MQXFA Magnet Aluminum Shells

The High-Luminosity LHC Accelerator Upgrade Project (HL-LHC AUP) is approaching the production phase of the US-contributed Q1 and Q3 Interaction Region Quadrupoles (MQXFA). The structures for the MQXFA prototypes were designed and inspected by the US-LARP (LHC Accelerator Research Program), AUP developed criteria, which will be used for the pre-series structures. The first two full-length prototypes with 4.2 m magnetic length, MQXFAP1 and MQXFAP2, were designed and assembled at Lawrence Berkeley National Laboratory (LBNL), and tested at Brookhaven National Laboratory (BNL). The end aluminum short shell of MQXFAP2 was fractured along the shell length during the test, and tests were stopped. Analytical and Finite Element analysis were performed in light of the graded procedure defined in the Structural Design Criteria to investigate the fracture failure for MQXFAP2. In this paper, we report the fracture analysis of the current shell design, including the elasto-plastic simulations with sub-model technique, and calculations with Linear Elastic Fracture Mechanics (LEFM). Test material properties are also presented. The results of this analysis explain why the end shell of MQXFAP2 failed, and suggest fillets on the end shell notches to meet the margin specified in the Structural Design Criteria.

Quench Protection of the First 4-m-Long Prototype of the HL-LHC Nb&lt;inline-formula&gt; &lt;tex-math notation="LaTeX"&gt;$_3$&lt;/tex-math&gt; &lt;/inline-formula&gt;Sn Quadrupole Magnet

The quadrupole magnets for the Large Hadron Collider (LHC) upgrade to higher luminosity are jointly developed by CERN and US-LARP (LHC Accelerator Research Program). These Nb $_3$ Sn magnets will be protected against overheating after a quench by a combination of heaters bonded to the coil outer surface and coupling-loss induced quench (CLIQ) units. The first 4-m-long prototype magnet, called MQXFAP1, was tested at the Brookhaven National Laboratory in stand-alone configuration. The magnet training campaign, consisting of 18 quenches, was interrupted due to the development of a short circuit between one heater strip and the coil. During the campaign, different quench protection schemes were implemented, including heaters attached to outer and inner layers, one CLIQ unit, and the energy-extraction system. The configuration including outer-layer heaters and CLIQ achieved the fastest current discharge, hence the lowest hotspot temperature. The electro-magnetic and thermal transients after a quench were simulated with the program STEAM-LEDET and found in good agreement.

Fabrication and Assembly Performance of the First 4.2 m MQXFA Magnet and Mechanical Model for the Hi-Lumi LHC Upgrade

The LHC accelerator research program (LARP), in collaboration with CERN and under the scope of the high luminosity upgrade of the Large Hadron Collider, is in the prototyping stage in the development of a 150 mm aperture high-field Nb3Sn quadrupole magnet called MQXF. This magnet is mechanically supported using a shell-based support structure, which has been extensively demonstrated on several R&D models within LARP, as well as in the more recent short (1.2 m magnetic length) MQXF model program. The MQXFA magnets are each 4.2 m magnetic length, and the first mechanical long model, MQXFA1M (using aluminum surrogate coils), and MQXFAP1 prototype magnet (the first prototype with Nb3Sn coils) have been assembled at the LBNL. In this paper, we summarize the tooling and the assembly processes, and discuss the mechanical performance of these first two assemblies, comparing strain gauge data with finite element model analysis, as well as the near-term plans for the long MQXF magnet program.

Summary of Test Results of MQXFS1—The First Short Model 150 mm Aperture Nb3Sn Quadrupole for the High-Luminosity LHC Upgrade

The development of Nb3Sn quadrupole magnets for the High-Luminosity LHC upgrade is a joint venture between the US LHC Accelerator Research Program (LARP)* and CERN with the goal of fabricating large aperture quadrupoles for the LHC interaction regions (IR). The inner triplet (low-β) NbTi quadrupoles in the IR will be replaced by the stronger Nb3Sn magnets boosting the LHC program of having 10-fold increase in integrated luminosity after the foreseen upgrades. Previously, LARP conducted successful tests of short and long models with up to 120 mm aperture. The first short 150 mm aperture quadrupole model MQXFS1 was assembled with coils fabricated by both CERN and LARP. The magnet demonstrated a strong performance at Fermilab's vertical magnet test facility reaching the LHC operating limits. This paper reports the latest results from MQXFS1 tests with changed prestress levels. The overall magnet performance, including quench training and memory, ramp rate, and temperature dependence, is also summarized.

Quench Protection Performance Measurements in the First MQXF Magnet Models

The European Organization for Nuclear Research (CERN) and U.S. LHC Accelerator Research Program (LARP) are jointly developing Nb $_3$ Sn quadrupole magnets to be installed in the LHC for its upgrade to higher luminosity. These magnets’ quench protection system will include a combination of quench heaters attached to the coil surfaces and coupling-loss-induced quench (CLIQ) units electrically connected to the magnets. Different protection elements have been characterized separately and simultaneously by implementing them on two 1.2-m-long model quadrupole magnets, tested at Fermi National Acceleration Laboratory and CERN, and one 4-m-long mirror magnet tested at Brookhaven Nation Laboratory. After analyzing the test data, their performances have been positively evaluated. Furthermore, the electrothermal transients occurring after a quench have been simulated with the LEDET software and the results are compared to experimental results. The preferred quench protection system configuration relies both on heaters and CLIQ. This solution is based on electrically robust components, achieves an effective reduction of the coils hot spot temperature after a quench, and offers increased redundancy against component failures.

Assessment of thermal loads in the CERN SPS crab cavities cryomodule11Work supported by the European Union HL-LHC Project and by US DOE through Brookhaven Science Associates LLC under contract No. DE-AC02-98CH10886 and the US LHC Accelerator Research Program (LARP). Research supported by the HL-LHC project.

As a part of the HL-LHC upgrade, a cryomodule is designed to host two crab cavities for a first test with protons in the SPS machine. The evaluation of the cryomodule heat loads is essential to dimension the cryogenic infrastructure of the system. The current design features two cryogenic circuits. The first circuit adopts superfluid helium at 2 K to maintain the cavities in the superconducting state. The second circuit, based on helium gas at a temperature between 50 K and 70 K, is connected to the thermal screen, also serving as heat intercept for all the interfaces between the cold mass and the external environment. An overview of the heat loads to both circuits, and the combined numerical and analytical estimations, is presented. The heat load of each element is detailed for the static and dynamic scenarios, with considerations on the design choices for the thermal optimization of the most critical components.

Performance of the First Short Model 150-mm-Aperture Nb3Sn Quadrupole MQXFS for the High-Luminosity LHC Upgrade

The U.S. LHC Accelerator Research Program (LARP) and CERN combined their efforts in developing Nb3Sn magnets for the high-luminosity LHC upgrade. The ultimate goal of this collaboration is to fabricate large aperture Nb 3Sn quadrupoles for the LHC interaction regions. These magnets will replace the present 70-mm-aperture NbTi quadrupole triplets for expected increase of the LHC peak luminosity up to 5 × 1034 cm –2s–1 or more. Over the past decade, LARP successfully fabricated and tested short and long models of 90 and 120-mm-aperture Nb3Sn quadrupoles. Recently, the first short model of 150-mm-diameter quadrupole MQXFS was built with coils fabricated both by LARP and CERN. The magnet performance was tested at Fermilab's vertical magnet test facility. This paper reports the test results, including the quench training at 1.9 K, ramp rate and temperature dependence, as well as protection heater studies.

Field Quality and Fabrication Analysis of HQ02 Reconstructed Nb3Sn Coil Cross Sections

Author(s): Holik, EF; Ambrosio, G; Carbonara, A; Dietderich, DR; Dimarco, J; Pong, I; Sabbi, GL; Santini, C; Schmalzle, J; Wang, X | Abstract: The U.S. LHC Accelerator Research Program (LARP) quadrupole HQ02 was designed and fully tested as part of the low-beta quad development for Hi-Lumi LHC. HQ02's design is well documented with full fabrication accounting along with full field analysis at low and high current. With this history, HQ02 is an excellent test bed for developing a methodology for measuring turn locations from magnet cross sections and comparing with CAD models and measured field. All four coils of HQ02 were cut in identical locations along the magnetic length corresponding to magnetic field measurement and coil metrology. A real-time camera and coordinate measuring equipment was used to plot turn corners. Measurements include systematic and random displacements of winding blocks and individual turns along the magnetic length. The range of cable shifts and the field harmonic range along the length are in agreement, although correlating turn locations and measured harmonics in each cross section is challenging.

Fabrication of First 4-m Coils for the LARP MQXFA Quadrupole and Assembly in Mirror Structure

The US LHC Accelerator Research Program is constructing prototype interaction region quadrupoles as part of the US in-kind contribution to the Hi-Lumi LHC project. The low-beta MQXFA Q1/Q3 coils have a 4-m length and a 150 mm bore. The design was previously validated on short, one meter models (MQXFS) developed as part of the longstanding Nb3Sn quadrupole R&D by LARP in collaboration with CERN. In parallel, facilities and tooling are being developed and refined at BNL, LBNL, and FNAL to enable long coil production, assembly, and cold testing. Long length scale-up is based on the experience from the LARP 90-mm aperture (TQ-LQ) and 120-mm aperture (HQ and Long HQ) programs. A 4-m long MQXF practice coil was fabricated to verify procedures, parts, and tooling. In parallel, the first complete prototype coil (QXFP01a) was fabricated and assembled in a long magnetic mirror, MQXFPM1, to provide early feedback on coil design and fabrication following the successful experience of previous LARP mirror tests.

Magnetic Measurements of the First Nb3Sn Model Quadrupole (MQXFS) for the High-Luminosity LHC

Author(s): DiMarco, J; Ambrosio, G; Chlachidze, G; Ferracin, P; Holik, E; Sabbi, G; Stoynev, S; Strauss, T; Sylvester, C; Tartaglia, M; Todesco, E; Velev, G; Wang, X | Abstract: The U.S. LHC Accelerator Research Program (LARP) and CERN are developing high-gradient Nb3Sn magnets for the high luminosity LHC interaction regions. Magnetic measurements of the first 1.5-m long, 150-mm aperture model quadrupole, MQXFS1, were performed during magnet assembly at LBNL, as well as during cryogenic testing at Fermilab's Vertical Magnet Test Facility. This paper reports on the results of these magnetic characterization measurements, as well as on the performance of new probes developed for the tests.

Assembly Tests of the First Nb3Sn Low-Beta Quadrupole Short Model for the Hi-Lumi LHC

In preparation for the high-luminosity upgrade of the Large Hadron Collider (LHC), the LHC Accelerator Research Program (LARP) in collaboration with CERN is pursuing the development of MQXF: a 150-mm-aperture high-field Nb3Sn quadrupole magnet. The development phase starts with the fabrication and test of several short models (1.2-m magnetic length) and will continue with the development of several long prototypes. All of them are mechanically supported using a shell-based support structure, which has been extensively demonstrated on several R&D models within LARP. The first short model MQXFS-AT has been assembled at LBNL with coils fabricated by LARP and CERN. In this paper, we summarize the assembly process and show how it relies strongly on experience acquired during the LARP 120-mm-aperture HQ magnet series. We present comparison between strain gauges data and finite-element model analysis. Finally, we present the implication of the MQXFS-AT experience on the design of the long prototype support structure.

Development of MQXF: The Nb&lt;sub&gt;3&lt;/sub&gt;Sn Low-&lt;inline-formula&gt; &lt;tex-math notation="LaTeX"&gt;$\beta$&lt;/tex-math&gt;&lt;/inline-formula&gt; Quadrupole for the HiLumi LHC

The High Luminosity (HiLumi) Large Hadron Collider (LHC) project has, as the main objective, to increase the LHC peak luminosity by a factor five and the integrated luminosity by a factor ten. This goal will be achieved mainly with a new interaction region layout, which will allow a stronger focusing of the colliding beams. The target will be to reduce the beam size in the interaction points by a factor of two, which requires doubling the aperture of the low-β (or inner triplet) quadrupole magnets. The use of Nb3Sn superconducting material and, as a result, the possibility of operating at magnetic field levels in the windings higher than 11 T will limit the increase in length of these quadrupoles, called MQXF, to acceptable levels. After the initial design phase, where the key parameters were chosen and the magnet's conceptual design finalized, the MQXF project, a joint effort between the U.S. LHC Accelerator Research Program and the Conseil Europeen pour la Recherche Nucleaire (CERN), has now entered the construction and test phase of the short models. Concurrently, the preparation for the development of the full-length prototypes has been initiated. This paper will provide an overview of the project status, describing and reporting on the performance of the superconducting material, the lessons learnt during the fabrication of superconducting coils and support structure, and the fine tuning of the magnet design in view of the start of the prototyping phase.

Measurements and Analysis of Dynamic Effects in the LARP Model Quadrupole HQ02b During Rapid Discharge

This paper presents the analysis of some quench tests addressed to study the dynamic effects in the 1-m-long 120-mm-aperture Nb3Sn quadrupole magnet, i.e., HQ02b, designed, fabricated, and tested by the LHC Accelerator Research Program. The magnet has a short sample gradient of 205 T/m at 1.9 K and a peak field of 14.2 T. The test campaign has been performed at CERN in April 2014. In the specific tests, which were dedicated to the measurements of the dynamic inductance of the magnet during the rapid current discharge for a quench, the protection heaters were activated only in some windings, in order to obtain the measure of the resistive and inductive voltages separately. The analysis of the results confirms a very low value of the dynamic inductance at the beginning of the discharge, which later approaches the nominal value. Indications of dynamic inductance variation were already found from the analysis of current decay during quenches in the previous magnets HQ02a and HQ02a2; however, with this dedicated test of HQ02b, a quantitative measurement and assessment has been possible. An analytical model using interfilament coupling current influence for the inductance lowering has been implemented in the quench calculation code QLASA, and the comparison with experimental data is given. The agreement of the model with the experimental results is very good and allows predicting more accurately the critical parameters in quench analysis (MIITs, hot spot temperature) for the MQXF Nb3Sn quadrupoles, which will be installed in the High Luminosity LHC.

Dimensional Changes of Nb3Sn Rutherford Cables During Heat Treatment

In high field magnet applications, Nb <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sub> Sn coils undergo a heat treatment step after winding. During this stage, coils radially expand and longitudinally contract due to the Nb <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sub> Sn phase change. In order to prevent residual strain from altering superconducting performances, the tooling must provide the adequate space for these dimensional changes. The aim of this paper is to understand the behavior of cable dimensions during heat treatment and to provide estimates of the space to be accommodated in the tooling for coil expansion and contraction. This paper summarizes measurements of dimensional changes on strands, single Rutherford cables, cable stacks, and coils performed between 2013 and 2015. These samples and coils have been performed within a collaboration between CERN and the U.S. LHC Accelerator Research Program to develop Nb <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sub> Sn quadrupole magnets for the HiLumi LHC. The results are also compared with other high field magnet projects.

Test Results of the LARP Nb3Sn Quadrupole HQ03a

The U.S. LHC Accelerator Research Program (LARP) has been developing Nb3Sn quadrupoles of increasing performance for the high-luminosity upgrade of the large hadron collider. The 120-mm aperture high-field quadrupole (HQ) models are the last step in the R&D phase supporting the development of the new IR Quadrupoles (MQXF). Three series of HQ coils were fabricated and assembled in a shell-based support structure, progressively optimizing the design and fabrication process. The final set of coils consistently applied the optimized design solutions and was assembled in the HQ03a model. This paper reports a summary of the HQ03a test results, including training, mechanical performance, field quality, and quench studies.

Fabrication and Analysis of 150 mm Aperture Nb&amp;lt;sub&gt;3&amp;lt;/sub&gt;Sn LARP MQXF Coils

The U.S. LHC Accelerator Research Program (LARP) and CERN are combining efforts for the HiLumi-LHC upgrade to design and fabricate 150-mm-aperture, interaction region quadrupoles with a nominal gradient of 130 T/m using Nb3Sn. To successfully produce the necessary long MQXF triplets, the HiLumi-LHC collaboration is systematically reducing risk and design modification by heavily relying upon the experience gained from the successful 120-mm-aperture LARP HQ program. First generation MQXF short (MQXFS) coils were predominately a scaling up of the HQ quadrupole design allowing comparable cable expansion during Nb3Sn formation heat treatment and increased insulation fraction for electrical robustness. A total of 13 first generation MQXFS coils were fabricated between LARP and CERN. Systematic differences in coil size, coil alignment symmetry, and coil length contraction during heat treatment are observed and likely due to slight variances in tooling and insulation/cable systems. Analysis of coil cross sections indicate that field-shaping wedges and adjacent coil turns are systematically displaced from the nominal location and the cable is expanding less than nominally designed. Lastly, a second generation MQXF coil design seeks to correct the expansion and displacement discrepancies by increasing insulation and adding adjustable shims at the coil pole and midplanes to correct allowed magneticmore » field harmonics.« less

Nb3Sn High Field Magnets for the High Luminosity LHC Upgrade Project

The high luminosity upgrade of the Large Hadron Collider at CERN requires a new generation of high field superconducting magnets. High field large aperture quadrupoles (MQXF) are needed for the low-beta triplets close to the ATLAS and CMS detectors, and high field two-in-one dipoles (11-T dipoles) are needed to make room for additional collimation. The MQXF quadrupoles, with a field gradient of 140 T/m in 150 mm aperture, have a peak coil field of 12.1 T at nominal current. The 11-T dipoles, with an aperture of 60 mm, have a peak coil field of 11.6 T at nominal current. Both magnets require Nb 3 Sn conductor and are the first applications of this superconductor to actual accelerator magnets. Collaboration between the US LARP (LHC Accelerator Research Program) and CERN is developing the MQXF magnets, whereas the 11-T dipole magnets are being developed by CERN and Fermilab. This paper reviews the status of Nb 3 Sn technology for accelerator magnets, discusses its main challenges, and discusses how the MQXF and 11-T designs are addressing them.

Performance of HQ02, an Optimized Version of the 120 mm &lt;formula formulatype="inline"&gt;&lt;tex Notation="TeX"&gt; $\hbox{Nb}_{3}\hbox{Sn}$&lt;/tex&gt;&lt;/formula&gt; LARP Quadrupole

In preparation for the high luminosity upgrade of the Large Hadron Collider (LHC), the LHC Accelerator Research Program (LARP) is developing a new generation of large aperture high-field quadrupoles based on Nb <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sub> Sn technology. One meter long and 120 mm diameter HQ quadrupoles are currently produced as a step toward the eventual aperture of 150 mm. Tests of the first series of HQ coils revealed the necessity for further optimization of the coil design and fabrication process. A new model (HQ02) has been fabricated with several design modifications, including a reduction of the cable size and an improved insulation scheme. Coils in this magnet are made of a cored cable using 0.778 mm diameter Nb <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sub> Sn strands of RRP 108/127 subelement design. The HQ02 magnet has been fabricated at LBNL and BNL, and then tested at Fermilab. This paper summarizes the performance of HQ02 at 4.5 K and 1.9 K temperatures.