Technology Development Lance Cooley TD / SRF Development Dept. / SRF Materials Group Leader
f Goals for SRF Materials R&D Goals for SRF Materials R&D Fermilab • Our job is to figure out Feb09 vs Nov08 how to advance the Target ILC state of the art. yield in • Goal: Advance the state 2012 of the art toward the 2012 ILC goal (90% Target ILC yield at 35 MV/m) 25 MV/m yield in 2009 – This goal also satisfies performance goals for Project X. Goal: Can we define • and approach even higher limits? 19 Ma 19 May 2009 y 2009 S SRF R F Revie view Coole oley – Technology De Deve velopment 2
f Baseline fabrication sequence Baseline fabrication sequence Fermilab Step Why? Tool / facility ASTM Spec, QA/QC Melt Nb Clean, high K Th E-beam melt RRR ~ 300 E Acc ∝ RRR 1/2 At niobium Forging Uniform props Forge Grain size spec vendor Roll Make sheets Mill, Oven Grain size spec, Proprietary surface finish spec Rx and level Ductility, High-vac Oven, Flatness spec flatness Proprietary Elongation spec Deliver ECS, RRR, Microscopy, mechanical meas. Form ½ cells Cavity shape Die + press Tune At cavity Iris weld Clean weld EBW + tooling RGA, qualification vendor (from inside) Dumbell weld Geometry EBW + tooling RGA, qualification (from outside) difficult End pcs weld EBW + tooling RGA, qualification 19 May 2009 19 Ma y 2009 S SRF R F Revie view Coole oley – Technology De Deve velopment 3
f Baseline processing sequence Baseline processing sequence Fermilab Step Why? Tool / Facility Diagnoses, QA Receipt Opt. Inspx, Dim. Ultrasonic tank (US) + Degrease ultra-pure water (UPW) Outer etch Better heat xfer BCP tool + Acid Temperature Bulk EP Fab. damage EP tool + Acid Raman, T, V(I) Wash Chem. Residue US + UPW Hydrogen 800 °C bake High-Vac Oven RGA Quench Shape changes Re-tune Tuning machine Smooth surface Fine EP EP tool + Acid Raman, T, V(I) Chem. Residue Wash US + UPW + alcohol? Dust Rinse HPR + UPW, class 10 Assemble Vac, Class 10 FE ( It works ) 120 °C bake Low-T oven Vert. test VTS Tmap, Opt Inspx 19 May 2009 19 Ma y 2009 S SRF R F Revie view Coole oley – Technology De Deve velopment 4
Issues lurk at every step because the art is based on Issues lurk at every step because the art is based on f recipes and not on understanding recipes and not on understanding Fermilab • Raw material • Tuning: Heat treatments soften metal, promote detuning Niobium is not “sheet metal” – – Each batch is different! • Chemistry – Grain texture affects later Acids are dangerous – forming and chemistry – Acid reactions are very sensitive Alternate: Ingot slices (Lg gr) – to process params, mat’l history Forming • EP does not obey “classic” – science; high flow is used – Shear is required to maintain thickness – shear bands – Cavity surface is complex – how promote dislocation etch pitting to model and control? – Keeping ductility imposes – Alternate: Non-HF process restrictions on raw material HPR: • • Welding – Ablative – What is being – Pits! Many mechanisms are removed? Damaged? plausible Assembly experience varies – – Tooling, vacuum artifacts Diagnoses: • – Vendor experience varies Can’t touch RF surface! – Remove forming history? – – Repair in situ? Alternate: hydroforming – ALD, etc.: New! What’s the payoff? • 19 May 2009 19 Ma y 2009 S SRF R F Revie view Coole oley – Technology De Deve velopment 5
f Optical inspection – key breakthrough! Optical inspection – ey breakthrough! Fermilab D. Sergatskov, C. Ginsburg FNAL Thermometry locates hot spots Hot spots correlate with location of defects (pits) Seeing the microstructure provides the feedback Seeing the microstructure provides the feedback WELD needed to drive the materials science! needed to drive the materials science! Hayano group, Kyoto Image enhanced by FSU 19 May 2009 19 Ma y 2009 S SRF R F Revie view Coole oley – Technology De Deve velopment 6
f Management to address issues Management to address issues Fermilab • FNAL cannot do everything – therefore we coordinate a comprehensive array of ~30 partners from academia, labs, and industry (next slide) – Many will be supported with ARRA funds – Primary reporting is via SRF Materials Workshop • FNAL is organizer • HEP, JLab, Cornell, FSU, MSU also on program committee • FNAL maintains QA/QC to support fab and processing • FNAL conducts some basic work and processing R&D • FNAL performs activities not easily done by partners – Pre-weld, coupon, and cavity acid work – HPR, assemble, and test – Diagnostics, including T-mapping, optical inspx., and ECS 19 Ma 19 May 2009 y 2009 S SRF R F Revie view Coole oley – Technology De Deve velopment 7
f U.S. Materials R&D Community U.S. Materials R&D Community Fermilab Cavity vendors AES Processing Science Niowave (+Roark) Niobium vendors FNAL PAVAC ATI Wah Chang JLab Sciaky HC Starck Cornell (Foreign vendors) (Foreign vendors) ANL Ohio State Mgmt. Northeastern FNAL Surface Science Nevada-Reno JLab Texas A&M FSU Cornell Black Labs U Chicago Interlaken IIT VCU Materials Science Maryland Penn. State ANL-APS Florida State ABLE EP William & Mary Michigan State Cabot Virginia Tech Northwestern Faraday Inc UIC 19 May 2009 19 Ma y 2009 S SRF R F Revie view Coole oley – Technology De Deve velopment 8
f Ties with international materials community Ties with international materials community Fermilab • Participate on organizing and program committees for SRF Workshop, TTC, Thin Film SRF Workshop • Integration with S0 and GDE periodic meetings • Broader interaction with large conferences and journals – ASC 2008 special session – ICMC 2009 plenary 19 Ma 19 May 2009 y 2009 S SRF R F Revie view Coole oley – Technology De Deve velopment 9
f Shepherding the Materials Community Shepherding the Materials Community Fermilab Labs’ role: • – Steer the agenda, define issues – Get samples to academics = coupons and pieces cut from cavities – Zero in on real defects = ECS, optical inspection, T-map – Develop processing = do work, modify based on understanding – Facilitate ideas = get 1-cell cavities to SBIRs, labs, academics – Drive vendor development = buy cavities, transfer processes – Test cavities from vendors and give feedback • Academics’ role: – Provide understanding based on materials, physics, and chemistry – Provide reality checks, define limits, describe mechanisms • Industry role: – Define the fabrication and processing realities – Engage in dialogues with academics and labs – Deliver cavities Generate new ideas (SBIR) – 19 May 2009 19 Ma y 2009 S SRF R F Revie view Coole oley – Technology De Deve velopment 10 10
f Means to fill the lab role Means to fill the lab role Fermilab • Routes to understanding require • Dedicated single-cell chemical control over all steps processing in IB4 – op. mid FY10 TD investment to support SRF We have our own Nb supply and – • conduct QA – ANL facility busy with 9-cell production – Also supports procurements – We need to vary parameters and ~1 ton eddy-current scanned by – try new ideas, too end of FY09 Dedicated lab area • – RRR and other diagnoses Dedicated HPR and assembly – • – SEM, Instron, CryoInstron (MSU) op. end FY09 • Coupons and single-cell forming & welding done by us • Dedicated single-cell test @ A0 We do the weld prep and etch – – Now op.; set up by 3.9GHz SRF – We presently rent Sciaky EBW – IB1 VTS busy with 9-cell – We plan to buy and support an • Tumbling machine – op. June 09 e-beam welder – ARRA Enables non-HF cavity R&D – • 1-cell inventory for R&D / SBIR Diagnoses – plan for dedicated • (16 3.9GHz + 18 1.3GHz) optical inspection 19 May 2009 19 Ma y 2009 S SRF R F Revie view Coole oley – Technology De Deve velopment 11 11
f New coupon tools New coupon tools Fermilab New witness sample fixture New witness sample fixture Same elliptical shape as 1.3 GHz cavity Ready for draft and build Fixture goes in-line with standard EP tool Sample New coupon EP tool New coupon EP tool In operation Heat exchanger for temperature control, pH monitoring, pumped acid 19 May 2009 19 Ma y 2009 S SRF R F Revie view Coole oley – Technology De Deve velopment 12 12
f Single-cell R&D FY09-FY12 Single-cell R&D FY09-FY12 Fermilab Approx. 50 cavities, 90 Processing R&D • • processes, and 125 tests – 2 ECS defect cavities – See A. Rowe breakout talk – 6 cavities planned – study material variations… – …then carbon removal • Vendor qualification – 6 cavities - EP science – Niowave-Roark, Accel and AES – 6 cavities from each • Alternate – Other N. America – 2 cavities - Large grain and single crystal cavities • Tool / facility qualification – 6 cavities - Non-HF – ANL facility processing, tumbling, CMP – Single-cell VTS – Planned hydroforming – Tumbling machine at FNAL New ideas • – EP industrialization at ABLE – 4+ cavities - ALD cap – Optical inspection – ALD multilayer, Nb/Cu benchmark – NR-4 – MgB 2 cavities – SBIR 19 May 2009 19 Ma y 2009 S SRF R F Revie view Coole oley – Technology De Deve velopment 13 13
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