3rd ILSF Advanced School on Radiation and Its Applications

September 14-16, 2013 in Synchrotron Design and Fabrication

Prepared by: Farhad Saeidi, Jafar Dehghani Mechanic Group , section, Institute for Research in Fundamental Sciences ILSF 1 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- • • • • • • • • applications” October K.Wille H. applications. H.Ghasem 1985. G.E.Fisher,”Iron Jack D. Belgium, Th.Zickler S.Fatehi, and Measurements”,and 6 January IPM, Sep. Sep. IPM, Einfeld Wiedemann Tanab , Thephysics ofParticleAccelerators 2013 M.khabazi 16‐25 , CERN Accelerator School Specialized, Course on ,Bruges, , ‘’ , , “Iron, Dominated Electromagnets Design,Fabrication, Assembly F.Saeidi, Magnets Sepember , June Dominated Magnets”,Stanford Linear Accelerator Center, ParticleAccelerator Physics I , “ firstILSF schoolsynchrotron on radiation and its ’’,Frascati, CAS, CELLS Nov. 2009. 2012. 2 nd ILSF school nd ILSFschool synchrotronon radiation and its 2011 References . , 2005. , Oxford University, , Springer, 1999. 2008. 2000. 2 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF-          Fabrication Procedure PrototypeILSF magnets Design Procedure Combined magnets Sextupoles Quadrupoles Dipoles Magnet types Light sourcesmagnets and IPM, Sep. Sep. IPM, 2013 OutLine 3 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 Lightsources and Storage LTB Linac Booster BTS magnets Diamond AcceleratorDiamond Complex 4 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 Magnet types ALBA,TPS, PAL,SLS,… CERN Brazilian light source

GEV), magnetic field field magnetic GEV), (> Use in high energylight Use in medium energymedium in Use Rarely usedRarely because of high prices, agingprices, high of 3 light sources( GEV), magnetic field field magnetic GEV), sources & > 2 etc T ≈ 3 ≤ 2 T 5 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 types

6 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF-  2. 1. Each magnet has IPM, Sep. Sep. IPM, Coils Ironleg , pole root, yoke( includesback pole ,…) 2013 2 main: parts 7 3rd ILSF School on Synchrotron Radiation and Its Applications • • • • • ILSF- parameters Dipolemain Productionof synchrotron radiation Extraction of particles from the accelerator Injectionof particles accelerator intothe Bendsthe electronsinsingle a curved trajectory. Has IPM, Sep. Sep. IPM, 2 poles, (BendingDipole magnet) 2013 2 coils GFR h L B (length) (half gap(half height) (magnetic field at center)(magneticat field (good region),field B y ( x ) = const Pole y=h profile eq.: By x 8 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, C - core 2013 StandardGeometries Dipole H - type High ampereturn High ampereturn

Window frameWindow 9 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, Normal Conducting Dipole MagnetConducting Dipole Normal 2013 µ (gaph height flux B magnetic o air permeability ) 10 3rd ILSF School on Synchrotron Radiation and Its Applications Coming K gets k: 2h: For Magnetic ‘Magnetic’ ILSF- geometry gap height gap a IPM, Sep. Sep. IPM, dipole: smaller from length: length > 2013 specific ∞, in L magnetic B case iron increases L constant constant magnetic Magnetic of: = length L iron = towards Saturation Pole + − +∞ (≈ 2 ∫ ∞ B * 0.56) dz ( width width 2 h B ) 0 the * length K < magnet gap height center (stray Beam directionBeam flux) 11 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- • • Strong • gradient fieldZerocenter in • • parameters Quadrupole main

4 Placed in straightin sectionsPlaced betweenbendingmagnets Focus the beam and prevent deviating poles, IPM, Sep. Sep. IPM, 4 2013 coils g (T/m) g R L g GFR ( length) (magneticgradient field ) (Aperture) (good region)field B y ( x ) = g x Pole profile eq.: Pole profile By xy = x 12 R 2 2 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, StandardGeometries Quadrupole 2013

13 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- field defined byfield definedgradient integration path split in along s along s along s IPM, Sep. Sep. IPM, Normal Conducting Quadrupole Magnet 2: 1: 3: 2013 & g 3 sections µ ra gradientg field o air permeability Aperture 14 3rd ILSF School on Synchrotron Radiation and Its Applications ‘Magnetic’ ILSF- k: R: Magnetic L magnetic geometry Aperture IPM, Sep. Sep. IPM, = length For L iron length 2013 + specific 2 RK > a iron Magnetic Quadrupole: constant constant length (≈ 0 . 45 length ) Beam direction 15 3rd ILSF School on Synchrotron Radiation and Its Applications parameters Sext • ILSF- to focusing to focusing particles on errors different with energy chromatic due aberration Sextupole correctmagnet upole main upole IPM, Sep. Sep. IPM, 2013 Sextupole magnet GFR R L B ‘‘ (Aperture) ( ( length) Sextupole component 3 Pole profile: (good region)field yx 2 − y B 3 y ( = x ) = R 1 ) 3 2 B ′ ′ x 2 0 0 16 x 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- Normal Conducting SextupoleNormal Magnet IPM, Sep. Sep. IPM, 2013 B µ R ´´ ´´ 0 Aperture air permeability Sextupole component 17 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- Amplitudes • • •  Quadrupole Dipole Functions Dipole + quadrupolesextupole + Dipole+ IPM, Sep. Sep. IPM, + 2013 cannot quadrupole generated + sextupole Combined magnets be varied by gxy y y pole = = independently 1 + 1 shape + h + B ( ′ B ′ gx 0 B gx ( 0 ) h x 0 (sum (sum ( 2 + 0 y ) B − 2 a ′ B ′ x scalar y 0 3 2 3 )

= potentials): cte . 18 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 Summary correct chromatic aberration focusebeam the Bend theelectron beam

19 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 Magnet Design 20 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, a) obtain the needed defined parameters defined current current from the 2013 MagnetProcedure Design Define Specifications b) choosing material choosingb) Electrical and Cooling Design Electrical Cooling and for the yoke yoke for the Perform Mechanical Design Design Mechanical c) profile designing designing profilec) computer optimization and pole ( by beam dynamics) beam by design d) Saturationtest tolerances in the goodthe tolerances in ) Checking field Checking e) field region 21 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- 2D design: (Poisson Superfish ,FEMM, Opera • • IPM, Sep. Sep. IPM, Profit Use ‐ pre from from 2013 processor symmetries or or modeler to reduce to build number geometry of of elements

2 D …) 22

3rd ILSF School on Synchrotron Radiation and Its Applications • • • • Common materials: used Today’s Today’s decarbonized • • ILSF- (Increase • • • • • M M 1200-100A(less than 0.003 % carboncontent &lessthan Magnetic AISI1010 A( 800-50A( 400-50A( Massive Packing factorshouldbebellow kept 98 %. rings. (Eddy current) Material Organic Homogeneity Magnetic by IPM, Sep. Sep. IPM, selection, standard: in % silicon content ) (max 0.1%carboncontent &max0.3%silicon permeability and 2013 or % silicon content) 0.01% carbon content& 1.7 %silicon content) 0.02% carboncontent &2.4%silicon iron is is atmosphere properties inorganic usually only and sorting mechanical cold cold reproducibility for cheaper, rolled, Decrease (permeability, Yoke Yoke – coating or dc the shuffling. magnets smaller non properties but in for ‐oriented materials hysteresis laminated among insulation carbon coercivity) should becoercivity)

can electro the content loss yokes and be magnets and ‐steel bonding. results adjusted are commonly used esp. in Booster commonly areused esp.in aging) % silicon content) 1.3% silicon of sheets within within in a better series by small small final magnetic can tolerances . be annealing enhanced properties 23 in 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- • • • • Electrical Coercivity: Specific Sheet Sheet IPM, Sep. Sep. IPM, thickness: weight: weight: 2013 resistivity Hc< 7 70 70 0 . . 60 3 (± @ ≤ ≤ 10 t 20 δ≤ ) ≤ ° A/m A/m C: C: 7 1 . . 85 5 0 mm g/cm . 16 (low 3 Si) Si) ≤ ρ ≤ 0 . 61 μΩm (high (high Si) 24 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 Pole Optimization 0 fieldquality leadsBAD i.e. tomore than multipoles these of amount the Rising . 1 % % SHIMMING is needed is SHIMMING 25 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- one Pole IPM, Sep. Sep. IPM, Pole Optimization- reaches Optimization 2013 the desire is field an iteration quality i process Shimming processShimming . e. < 10 -4 & should be continued

till 26 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- ILSF Dipole, Quadrupole & Sextupole& shimsQuadrupole ILSF Dipole, IPM, Sep. Sep. IPM, 2013 Dipole Quadrupole

Sextupole 27

3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- B IPM, Sep. Sep. IPM, 0 Dipole = const B ( x 2013 ) I central s field atthe each pointcalculated by simulation Field QualityCalculations field ∆ B = B Quadrupole B − B 0 0 B = 0 g 0 x B Sextupole 0

= 1 2 B 0 ′ ′ x 28 2 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF-

∆B/B0 - 40 IPM, Sep. Sep. IPM, - 30 2013 - 20 - 10 - - - 0 0 0 - - . . . 0 0 025 015 005 . . X[mm] 01 02 0 0 10 20 30 40

∆B'/B'0 - 30 - 20 - 10 - - - - - 0 0 0 0 0 0 0 ...... 005 004 003 002 001 001 002 X (mm) X 0 0 10 20 29 30 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 Saturation test 30 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 Harmonic analysis

31 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 Harmo nic analysis nic & Dynamic Aperture & 32 3rd ILSF School on Synchrotron Radiation and Its Applications all Unlike Unlike • • • • 3 ILSF- Magnets End End The The D design isD regions IPM, Sep. Sep. IPM, longitudinal effects effects 3D design:(Radia,Tosca,Mermaid,Flux 2 D where , in 3 , in 2013 with with from from in necessary to study : D: D: the the current field coils yoke aperture distribution density density is large have compared to to be be modeled modeled to the length completely 3D…)

33 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- • • Quadrupoles: • Dipoles: maintain that way a such in chosen Chamfer be should • Sextupoles: Depth Rogowsky roll Usually Angular good 3 D IPM, Sep. Sep. IPM, codes Longitudinal field and not cut magnetic 2013 or or angle region chamfered at measurements off off the adjusted or or length length end angular using constant constant shimming (Chamfering) cut across the 34 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, Good Field Region Field Good Magnetic Length Magnetic Good Field Region Field Good Magnetic Length Magnetic Parameter Gap height Gap Parameter Gap height Gap Field Field 2013 ILSF Prototype Magnet ± 155 32 0 Value 18mm . ± 34 72 Value 50 mm 20mm 0 cm . 5 mm T cm T C - H TypeMagnet Dipole - Type Magnet Dipole

I 35 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, Sextupole Strength Good Field Region Field Good Good Field Region Field Good Magnetic Length Magnetic Magnetic Length Magnetic Aperture radius Aperture Aperture radius Aperture Field Gradient Parameter Parameter 2013 ILSF Prototype Magnet 750T/m2 ± ± 30 23T/m 36mm Value Value 24 26 21mm 18mm mm cm cm Quadrupole Magnet Sextupole Magnet II 36 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- Gradient Mechanical Length Field ∆B/B Field RegionGood Gap Magnet specifications . . . Main Objectives: - IPM, Sep. Sep. IPM, B Parameter magnetic steel. Toavailable theif find lowcarbon steel isas capableusing of To developfabrication procedurestechniques. and To compare the measurement results with designdata. 0 - B' prototype 2013 0.03 % C Unit T/m mm mm mm T - H. PrototypeH. < 1 500 ± 0.5 × 34 0.01 % 20 - Chemicalsteel componentsof 10 Si - 4 H - Type magnet dipole 0.24 % Mn Magnetic specificationsmaterialof 0.011 % P 0.016 % S 37 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, Physicaland maindesign dimensions 2 D magnetic design magnetic design D 2013 Main dimensions Main - FEMM 3 D magnetic and chamfer design - RADIA

38 3rd ILSF School on Synchrotron Radiation and Its Applications Copper area Copper Reynolds number Reynolds circuit per drop Pressure speed water Cooling rise temperatureWater coil per circuit water of Number coil per Power coil per drop Voltage Density Current Cooling channel width channel Cooling height channel Cooling width Conductor height Conductor pancake per turn of Number coil per pancakes of Number coil per turn of Number current Operating coil per -turns ampere Total Specific resistance Resistance per coil Resistance per ILSF- IPM, Sep. Sep. IPM, Parameter 2013 Electricaland cooling design Design Value Design 790.24 23.45 0.018 1776 6900 7.79 1.02 4.33 6.42 1.81 8.66 4.05 0.08 101 10 34 68 8 2 2 Ohm A/mm Ohm mm Unit × m/s mm mm mm mm bar W C mm A A V - - - - - ̊ 2 2 2 /m 39 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 Stacking fixture Winding fixture 40 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, Washedlaminationsdried and Laser cutting Laser of 2013 laminations resin twomixing the componentsof 41 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 Coating the and length the procedure packing of packed factor has laminations been is measured done by by use measuring of brush, 42 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 43 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- wind In IPM, Sep. Sep. IPM, order from to 2013 the have middle two ends for each of the layers coil and in the we outer need to side have the even coil should layers 44 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- The machiningprocedure a in isway done to preventdelamination toand usethe IPM, Sep. Sep. IPM, common referencepointyokesboth on to reach todefined tolerances 2013 45 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 46 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 47 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 48 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 ILSF Prototype

Quadrupole Magnet

49 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- Magnetic length Field RegionGood Gradient Aperture radius Magnet specifications IPM, Sep. Sep. IPM, Parameter - B' 2013 0.01 % C Unit T/m mm mm mm Specification Quadrupole of H. PrototypeH. Chemicalsteel componentsof 1.7 % Si 260 ± 30 23 18 0.24 %

Mn B(T) 0 0 0 0 1 1 1 1 ...... 2 4 6 8 2 4 6 8 0 1 2 0 Magnetic specificationsmaterialof 2000 0.037 % P 4000 Magnet H(A/m) 6000 8000 S - 10000 12000 50 M 800 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2 D magnetic design magnetic design D Main dimensions Main 2013 - Poisson

∆B'/B'0 - 40 - 30 - 20 Field tolerancesField Pole profile - 10 - - - - - X (mm) X 0 0 0 0 0 0 0 ...... 005 004 003 002 001 001 002 0 0 10 20 30 51 40 3rd ILSF School on Synchrotron Radiation and Its Applications Total Amp Total turns per coil per turns turns per coil per turns ofNumber current Operating Parameter coil per pancakes ofNumber length Mechanical height Conductor width width Cooling channel height Cooling channel width Conductor ILSF- IPM, Sep. Sep. IPM, - Unit mm mm mm mm At m A - - 2013 No pancakes .0233 value 6553 96.4 4.05 6.42 1.81 8.66 68 Electrical and coolingElectrical design and Current densityCurrent Voltage drop drop Voltage magnet Power per Parameter Copper area rise temperature Water water circuits ofNumber number. Reynolds Pressure drop speed water Cooling A/mm mm Unit m/s KW bar V C - - 2 2 23.45 value 10.0 2441 4.16 1.27 2.5 6.7 25 4 ° 52 3rd ILSF School on Synchrotron Radiation and Its Applications General Drawing ILSF- Saturation IPM, Sep. Sep. IPM, 2013 53 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- Laser cutting Laser of IPM, Sep. Sep. IPM, & wirecut 2013 laminations 54 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 55 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, vacuum 2013 Presure impregnation ( assembling Yoke machining Magnetic Measurement VPI) 56 3rd ILSF School on Synchrotron Radiation and Its Applications y (mm) 20 10 12 14 16 18 ILSF- 8 30 IPM, Sep. Sep. IPM, 32 34 2013 B'' (T/m2) 36 1100 1300 1500 500 700 900 X (mm) 38 90 100 40 110 42 120 44 Sextupole Magnet 130 46 140 150 Actual 160 Design Theory I (A) I 170

B(T) 180 Theory 0 0 0 0 1 1 1 1 ...... Prototype 0 1 2 4 2 6 8 2 4 6 8 190 0 200 2000 210 4000 220 230 H(A/m) 6000 240 8000 250 10000 12000 57 M 800 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 Sextupole Design 58 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- conductor dimensions conductor Number of pancakes per coil coil per turns of Number Operatingcurrent coil per Amp total Parameter than 1160) than largerbe Reynold No.(should coil per Pressure drop waterCooling speed Water temperature rise magnet Number of water circuits per Power permagnet Voltage droppermagnet copper in Current density Copper area Waterdiametertube cooling IPM, Sep. Sep. IPM, - turns per coil per turns 2013 Electrical and cooling design 6.5 x 6.5 mm 6.5 x 6.5 No pancakes 38 129 A 4902 A Value 2500 6.22 bar 1.43 m/s 9.0° 3 Watt1553.85 12.05 V 3.95 A/mm 32.62 mm 3.5 mm C 2 2 2 59 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, Magnetic length Deflecting angle Bending radius Gradient field Gap Height Gap Parameter Field GFR 2013 Bending Magnet Prototype Degree Unit T/m mm mm m m T 6 14. 0 1.55 ± BE . 32 429 . 0 18 72 01 1 60 3rd ILSF School on Synchrotron Radiation and Its Applications ILSF- IPM, Sep. Sep. IPM, 2013 Thank youThank For yourattention 61