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f Fermilab SRF Cavity Processing for SRF Cavity Processing for Project X and ILC R& D Allan Rowe Allan Rowe f Outline Outline Fermilab Cavity processing program overview Lab processing facilities, recent accomplishments and

  1. f Fermilab SRF Cavity Processing for SRF Cavity Processing for Project X and ILC R& D Allan Rowe Allan Rowe

  2. f Outline Outline Fermilab • Cavity processing program overview • Lab processing facilities, recent accomplishments and p g , p upgrade plans. • Processing requirements for Project X and ILC R&D. • Processing requirements for Project X production • Processing requirements for Project X production. • Planned processing recipes for production. • ARRA--EP Industrialization and Eco-friendly processing May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 2

  3. f Cavity Processing Program Cavity Processing Program Fermilab • There are two missions to serve: – Prepare for Project X cavity production—i.e. increase lab-based capacity and industrialize as much processing as is practical to ensure high yield. – R&D and process improvement reach ILC goals • These missions intersect across facilities, schedules and people. • Both missions overlap significantly. Both missions overlap significantly – High yield throughput – Gradient improvement – Process simplification – Process modification – Alternative technologies Alternative technologies May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 3

  4. f S0 Processing Cycle - S0 Processing Cycle - Vert. Test ert. Test Fermilab Process Step Required Tool Clean & Degrease Clean & Degrease Ultrasonic Tank + UPW Ultrasonic Tank + UPW Outside BCP (20um) BCP Tool Bulk Electropolish (120 um) EP Tool Ultrasonically Clean Ultrasonic Tank + UPW FAILURE Hydrogen Degasification Vacuum Oven (800C) MODES RF Tuning Tuning Machine US Clean + Light EP (20 um) EP Tool + US Tank + UPW Alcohol Rinse + US Clean Ultrasonic Tank + UPW Quench ! High Pressure Rinse High Pressure Rinse HPR Tool + UPW HPR Tool + UPW FE! Clean Assem. & Evacuation Vacuum Skid + Class 10 Low Temperature Bake Vacuum Oven (120C) Vertical Test May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 4

  5. f Processing Cycle – Processing Cycle – Horiz. Test oriz. Test Fermilab Process Step Process Step Required Tool Required Tool FAILURE Helium Vessel Welding EB/TIG Welder MODES Ultrasonically Clean y Ultrasonic Tank + UPW Light BCP or EP (20um) BCP or EP Tool Quench! Alcohol Rinse + US Clean Ultrasonic Tank + UPW High Pressure Rinse HPR Tool + UPW FE! Vacuum Skid + Class 10 Clean Assem. & Evacuation cleanroom cleanroom Horizontal Test or String Assembly May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 5

  6. f JLab Processing & Facilities JLab Processing & Facilities Fermilab • Full complement of tools tools – EP, BCP, HPR, Vacuum oven, UPW, etc. • Production ready P d ti d – Capacity 40 EP-VT/yr JLab EP Tool • Upgrade requests • Upgrade requests – HPR System – UPW System – EP Tool spares – Next gen. EP technology (VEP) – VTA improvements JLab HPR & BCP Tools May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 6

  7. f JLab Processing & Facilities JLab Processing & Facilities Fermilab • FY09 pace of 30 EP/30 VT cycles—16 thus far • Vetting cavity vendors and improving procedures • FY10 will continue throughput and upgrade tools 0 co t ue t oug put a d upg ade too s Info. from: R. Geng, B. Rimmer, Jefferson Lab May 18-19, 2009 May 18-19, 2009 DOE SRF Review DO SRF Review 7

  8. f Cornell Processing & Facilities Cornell Processing & Facilities Fermilab • Growing collaboration with FNAL • Specific efforts – 2 nd sound instrumentation instrumentation – Vertical EP • Vertical EP Tech. transfer to industry. f i d (AES) • R&D capacity is 12 R&D capacity is 12 EP-VT cycles/year. • May repair pitted Cornell 2 nd sound Cornell vertical cavities with tumbling setup. EP tool. Provided by: Z. Conway, Cornell University May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 8

  9. f ANL/FNAL Proc. & Facilities ANL/FNAL Proc. & Facilities Fermilab • Operational Tools – EP for 1 and 9 cell EP for 1 and 9 cell – HPR – UPW + US Cleaning – Vacuum system – Clean assembly SCSPF EP Tool and S. Gerbick • 1-cell Program – Proven operational – FE free processing – >40MV/m, high Q – US vendor verif. US vendor verif Cleanroom tooling. G. Wu with US tank & hoist. May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 9

  10. f ANL/FNAL Proc. & Facilities ANL/FNAL Proc. & Facilities Fermilab • 1-cell work—Great! – Most tested w/o FE • 9-cell commissioning *still FE issues* – Improvement plans Improvement plans underway • Current capacity – 30 9-cell cavities/yr – 20 1-cell cavities/yr • Upgrade capacity Upgrade capacity – 80 9-cell cavities/yr – 20 1-cell cavities/yr – Add 3 operators to Add 3 t t D. Bice with cavity cart and HPR tool. reach capacity. May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 10 10

  11. f ANL/FNAL Proc. & Facilities ANL/FNAL Proc. & Facilities Fermilab Plans for Upgrades and FY10 Goals • Purchase with ARRA funds—800C vacuum oven • Purchase with ARRA funds—800C vacuum oven • Purchase 1-2 more 120C baking systems • Purchase critical items to improve redundancy at p y ANL/FNAL SCSPF • Identify & Train 3 more full-time operators • Achieve 6-8 EP/HPR cycles/month • Longer term plans – Flash EP/BCP fully dressed cavities Flash EP/BCP fully dressed cavities – Commission 2 nd HPR and assembly area in ANL cleanroom – Commission ICPA for 1-cell Program by 2011 C i i ICPA f 1 ll P b 2011 (L. Cooley Talk) May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 11 11

  12. f Facility Polishing Capacities Facility Polishing Capacities Fermilab FNAL JLab Cornell ANL/FNAL Total ICPA ICPA Current 30+/year 1-cell 20/year 50/year (2011) Throughput oug pu Current 9-cell EP-VT 40/year 12/year (1) 30/year 82/year Throughput Maximum Production 100/year (2) 100/year (2) 200/year EP/VT Th Throughput h t (1)Cornell to remain R&D only (2)JLab & ANL/FNAL capacity assumes an operating staff increase of 2-3 at each facility f from current levels t l l May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 12 12

  13. f R&D Processes -- R&D Processes -- Project X + ILC Project X + ILC Fermilab R&D Processing: Years 2009-2012 Polishing Polishing VT (HT) Cavity type Cavities Processes Cycles Cycles 1 Cell 1.3 GHz, EP, CMP, 50 50 90(EP) 90(EP) 125 125 β 1 β =1 ALD BP BCP ALD, BP, BCP 9 Cell 1.3 GHz, EP, CMP, 88 230(EP) 130(70) β =1 ALD, BP SSR, TSR BCP, EP 8 24 12 (8) EP= Electropolishing CMP= Chemical Mechanical Polishing CMP Ch i l M h i l P li hi ALD= Atomic Layer Deposition BP= Barrel Polishing BCP= BCP= Buffered Chemical Polishing Buffered Chemical Polishing May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 13 13

  14. f R&D Processing & Testing Plan R&D Processing & Testing Plan Fermilab R&D EP/BCP Cycles 1-cell 9-cell SSR/TSR 140 120 100 80 60 40 20 20 0 2009 2010 2011 2012 • Chart shows anticipated totals • Chart shows anticipated totals. • Industrial effort may increase both 1-cell and 9-cell polishing cycles. • SSR/TSR polishing performed in ANL G150 facility. SSR/TSR li hi f d i ANL G150 f ilit May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 14 14

  15. f R&D Processing & Testing Plan R&D Processing & Testing Plan Fermilab 9-Cell Horizontal Test Vertical Test Cycles Cycles 1-cell 9-cell SSR/TSR 30 100 100 25 80 20 60 15 40 10 20 5 0 0 0 0 2009 2010 2011 2012 2009 2010 2011 2012 • Throughput estimates are based on facility capacity and g p y p y anticipated personnel and cavity availability. • Approx. 50% of 9-cell cavities to be horizontally tested. • SSR/TSR tested in separate HINS facility SSR/TSR tested in separate HINS facility May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 15 15

  16. f Project X Production Project X Production Fermilab Installed Production Cavity type Cavities Cavities 9 Cell 304 340 1.3 GHz, β =1 9 Cell 9 Cell 64 70 1.3 GHz, β =0.81 SSR1 18 18 SSR2 33 38 TSR 42 49 TOTAL TOTAL 461 461 520 520 • Production Years: 2013-2015 • Extra cavities are due to yield and 10% spares Extra cavities are due to yield and 10% spares • Some spares from R&D program May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 16 16

  17. f Yearly Production Processing Yearly Production Processing Fermilab Production Years 2013-2015 Light Bulk EP BCP Light EP Cavity Cavity BCP BCP Vertical Vertical Horizontal Horizontal Cycles Cycles Cycles type Cycles Tests Tests Industry Industry Labs Labs 9 Cell 140 140 170 155 50 (eliminated) SSR1, SSR2, 35* 75* 40* 20* TSR * TOTAL 140 175 170 75* 195 70 (minimum) • Assumed cavity yield at 25 MV/m = 90% through HT Assumed cavity yield at 25 MV/m 90% through HT • Industry must perform bulk EP and outside BCP • ANL/FNAL + JLab can perform light EP for VT • Flash BCP post Ti vessel welding may be eliminated • Flash BCP post Ti vessel welding may be eliminated *SSR/TSR cavity recipes and test areas not yet defined May 18-19, May 18-19, 2009 2009 DO DOE SRF Review SRF Review 17 17

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