SRF2013 - List of Authors (Matheisen, A.)

Paper

Title

Page

The Challenge and Realization of the Cavity Production and Treatment in Industry for the European XFEL

18

W. Singer, J. Iversen, A. Matheisen, H. Weise
DESY, Hamburg, Germany
P. Michelato
INFN/LASA, Segrate (MI), Italy

The main effort in production of 1.3 GHz cavities for the EXFEL was dedicated to transfer the superconducting technology to the industry. These know how transfer is executed by DESY and INFN/LASA team. The preparation phase based on prototype cavities covered: qualification of potential vendors for material and cavity fabrication; work out recipe and strategy for qualification of the infrastructure for cavity surface treatment at industry; definition of the quality management strategy, documentation and electronically data exchange. Production of 800 series cavities on the principle “build to print” is contracted to companies Research Instruments and Ettore Zanon. High purity niobium and NbTi for resonators provides DESY. The principles of the material and cavities production in conformity with European Pressure Equipment Directive are developed together with the notified body. New or upgraded infrastructure has been established at both companies. The first several tens of series cavities have been produced and treated. Most of the cavities handed over to DESY up to now fulfill immediately the EXFEL specifications. The cavity production for EXFEL will be finished mid of 2015.

Slides MOIOA03 [7.394 MB]

MOP039

Strategy of Technology Transfer of EXFEL Preparation Technology to Industry

197

A. Matheisen, J. Iversen, A. Schmidt, W. Singer
DESY, Hamburg, Germany
P. Michelato, L. Monaco
INFN/LASA, Segrate (MI), Italy

For the EXFEL a specification for the cavitiy preparation procedures (R1)was set up and handed to the industrial companies. Basing on this specification companies hard ware as well as process flows were set up. Beside this specified part of the preparation technique the companies personal needed to be educated and the processes ramped up. To check the quality of the infrastructure, status of education of personal and correct set up of process flows, so called Dummy (DCV) - , Reference (RCV ) and Pre-series (PCV) cavities were assigned. We report on the general strategy applied for the EXFEL technology transfer on cavity preparation and the results obtained on the qualification cavities.
R1) Series Surface and acceptance test preparation of superconducting cavities for the European Xfel (XFEL/A - D) JUNE 30, 2009

MOP040

Industrialization of European XFEL Preparation Cycle “Final EP ” at Research Instruments Company

201

A. Matheisen, N. Krupka, M. Schalwat, A. Schmidt, M. Schmökel, W. Singer, B. van der Horst
DESY, Hamburg, Germany
P. Michelato, L. Monaco
INFN/LASA, Segrate (MI), Italy
M. Pekeler
RI Research Instruments GmbH, Bergisch Gladbach, Germany

In the Specification for XFEL Cavity preparation (R1) two different preparation sequences are presented. Research Instruments Company as one of the two companies contracted for XFEL cavity production and preparation has chosen the so called “final EP” cycle. Major infrastructure components like EP facility and the BCP facility were pre- qualified. This existing and the new set up areas like the cleanroom are distributed over the ground area of the industrial park Bergisch Gladbach. The process flow given in the DESY specification needed adaptation to this scenario. Additional infrastructure beside the once specified needed to be set up to ensure the same quality of processes even with a changed work flow. The general lay out of the facility, matched work flow of preparation and test results of resonators processed by RI company in their infrastructure will be reported.
(R1) Series Surface and acceptance test preparation of superconducting cavities for the European Xfel (XFEL/A - D) JUNE 30, 2009

MOP042

Quality Control and Processes Optimization for the EXFEL Superconducting Cavities Series Production at Ettore Zanon spa

208

L. Facci, D. Rizzetto
Ettore Zanon S.p.A., Nuclear Division, Schio, Italy
G. Corniani
Ettore Zanon S.p.A., Schio, Italy
A. Matheisen
DESY, Hamburg, Germany
P. Michelato, L. Monaco
INFN/LASA, Segrate (MI), Italy

The construction of the European XFEL forced the first mass production of Niobium bulk SRF cavities. In this context Ettore Zanon S.p.A. built a fully new facility designed to produce four fully treated and He tank equipped cavities per week, ready to be tested at DESY. The facility already reached the foreseen production rate. The guarantee of the highest quality of the resonators produced requires a very strict quality control plan. At the same time, the requirements of the industrial production in terms of time, cost and productivity must be satisfied. As a consequence processes must be standardized and working times optimized. In the following, after the description of the production facility, we would like to highlight and discuss the strategies and arrangements adopted in the various critical fields (clean room, vacuum, etc.) to ensure the foreseen results. Moreover correlation between cavities performances and production cycle parameters will be investigated and discussed.

MOP043

ILC-HiGrade Cavities as a Tool of Quality Control for European XFEL

212

A. Navitski, E. Elsen, B. Foster, J. Iversen, A. Matheisen, D. Reschke, W. Singer, X. Singer, L. Steder, M. Wenskat
DESY, Hamburg, Germany
R. Laasch, Y. Tamashevich
University of Hamburg, Hamburg, Germany

Funding: BMBF, Helmholtz Association, ILC-HiGrade, FP7 (CRISP), Alexander von Humboldt Stiftung/Foundation
The EXFEL order for SRF cavities includes 24 cavities, which are part of the ILC-HiGrade program. Initially, these cavities serve as quality control (QC) sample extracted from the EXFEL cavities series production on a regular basis. The QC and quality assurance (QA) include all processing steps of the EXFEL cavities. To maximize the information from these so-called QC cavities, a surface mapping technique is applied in a second cold RF test. There the cavities delivered have experienced identical treatment of the inner surface with the exception of mounting of the Helium vessel. After the normal acceptance test at the cavity RF measurement facility, the cavities are removed from the production flow. Further quality assurance steps beginning with a detailed RF test with surface mapping followed by a high resolution optical inspection (OBACHT) are carried out to improve the understanding of defects in close collaboration with the standing experts engaged in the EXFEL production. Results of the first QC cavities tests as well as planned further R&D will be presented and discussed.

MOP045

Electropolishing for EXFEL Cavities Production at Ettore Zanon SpA

220

M. Rizzi
Ettore Zanon S.p.A., Schio, Italy
A. Gresele
Ettore Zanon S.p.A., Nuclear Division, Schio, Italy
A. Matheisen, N. Steinhau Kühl
DESY, Hamburg, Germany
P. Michelato
INFN/LASA, Segrate (MI), Italy

A new horizontal electropolishing (EP) facility has been implemented by Ettore Zanon SpA for the series production of the EXFEL cavities produced by the company. According to EXFEL specification a bulk EP of at least 100 micron is the first step of the surface treatment for high performances. Particular attention has been dedicated to find the best configuration during qualification of the system. Correlation between process variables, RF tests at room temperature at Zanon and vertical RF tests at 2 K at DESY have been investigated and the Niobium removal optimized. The facility has been designed for industrial scope, in order to guarantee the required quality and production rate of 4 cavities per week. One of the most important aspects has been the system automation to have complete control of the process.

MOP047

Set up of Production Line for EXFEL Beam Position Monitor and Quadrupol Units for Cavity String Assembly at CEA

224

M. Schalwat, M. Koepke, A. Matheisen, H. Weitkämper
DESY, Hamburg, Germany

The super conducting (s.c.) accelerator models of the EXFEL consist of eight s.c. resonators, one s.c. quadrupol magnet and one beam position monitor. These components are connected inside ISO 4 cleanroom at CEA Saclay to a so called cavity string under the guidance of the XFEL WP 09 activities. The eight s.c. cavities are handed from DESY to CEA for string assembly after successful RF test. The beam- position monitor and Quadrupol units (BQU) are assembled and cleaned in the DESY cleanroom at DESY Hamburg to the same standard’s of cleanliness as requested for s.c. Cavities. The completed BQU units are handed over to CEA IRFU / WP 9 in “ready for installation to cavity string“ status. The setup of infrastructure, the qualification of processes and transport as well as the ramp up to a delivery rate of 1 BQU per week will be presented.

MOP048

PED Requirements Applied to the Cavity and Helium Tank Manufacturing

227

A. Schmidt, J. Iversen, A. Matheisen, W. Singer
DESY, Hamburg, Germany

For the European XFEL more than 800 Cavities are manufactured by industrial partners. Each cavity is housed in an individual cryo vessel, the so called helium tank. All vessels are made from titanium and manufactured by industry as well. The cavity, welded into its helium tank, is a pressure loaded part and has to follow the pressure equipment directive - PED (97/23/EC). Setting up a series production of cavities and helium tanks by different vendors according given standards, was the task of the EXFEL WPG-1 LINAC-WP04. In cooperation with the TUEV-Nord as the notified body, DESY is responsible for the qualification of design, material in use and reasonable tests to get a certificate for pressure bearing parts.

MOP049

Progress and Experiences of Series Production of Helium Tanks With DESY as a Subcontractor for RI

231

A. Schmidt, J.A. Dammann, A. Daniel, A. Matheisen
DESY, Hamburg, Germany

DESY acts as a subcontractor for helium tanks, for one of the cavity manufacturer in charge, for the EXFEL cavity production. Here the full responsibility of production, quality and warranty of these parts is at DESY. Therefore on 400 out of the total of 800 helium tanks, DESY has to set up a logistic of incoming inspection, documentation, storage and distribution. Special effort is made to archive a free of doubts interconnection and integration of the cavity into the helium tank. After more than 300 units produced a review and statistic is provided.

TUP056

Industrialization of European XFEL Preparation Cycle “BCP Flash” at Ettore Zanon Company

547

A. Matheisen, N. Krupka, M. Schalwat, A. Schmidt, W. Singer, N. Steinhau Kühl, B. van der Horst
DESY, Hamburg, Germany
G. Corniani
Ettore Zanon S.p.A., Schio, Italy
P. Michelato, L. Monaco
INFN/LASA, Segrate (MI), Italy

In the Specification for XFEL Cavity preparation (R1) two different preparation sequences are presented. Ettore Zanon Company as one of the two companies contracted for XFEL cavity production and preparation has chosen the so called BCP flash cycle. To fulfill the requested work flow and quality of infrastructure and processes, the company set up a complete new infrastructure in refurbished fabrication halls. The layout of the facility, set up of work flow of preparation and test results of resonators processed by E.Zanon in their infrastructure will be reported.
(R1) Series Surface and acceptance test preparation of superconducting cavities for the European Xfel (XFEL/A - D) JUNE 30, 2009

TUP094

Influence of Heat Treatments on Field Emitters on Nb Crystals

690

S. Lagotzky, G. Müller
Bergische Universität Wuppertal, Wuppertal, Germany
A. Matheisen, D. Reschke
DESY, Hamburg, Germany

Funding: Funding by HGF Alliance and the BMBF project 05H12PX6
Systematic investigations of the enhanced field emission (EFE) of HPR-cleaned large grain (LG) and single crystal (SC) Nb samples (Ra < 0.5μm) revealed an exponential increase of the emitter number density N with electric surface field Es and strong activation effects of the remaining particulates. Different types of EFE activation were observed: by high E partially combined with a micro-discharge or by heat treatments (HT) [1]. In cavities, EFE activation might also occur due to enhanced rf losses of particulates. Therefore, we have started a test series with two LG and two SC typically prepared Nb samples (40 μm BCP, 140 μm EP and HPR at DESY). At first all emitters (1 nA) up to Es = 160 MV/m were localized by means of correlated field emission microscopy (FESM). Then systematically varied in-situ HT between 122°C (24 h) and 400°C (2 h) were applied to investigate the activation of emitters due to the change of the natural Nb oxide. For all samples a significant increase of N with stronger HT up to 32 emitters/cm² at 400°C were obtained resulting in some activated emitters already at Es = 40 MV/m. Final SEM images of the activated emitters will also be discussed.
[1] A. Navitski et. al, subm. to PRSTAB 2013

Paper	Title	Page
MOIOA03	The Challenge and Realization of the Cavity Production and Treatment in Industry for the European XFEL	18
	W. Singer, J. Iversen, A. Matheisen, H. Weise DESY, Hamburg, Germany P. Michelato INFN/LASA, Segrate (MI), Italy
	The main effort in production of 1.3 GHz cavities for the EXFEL was dedicated to transfer the superconducting technology to the industry. These know how transfer is executed by DESY and INFN/LASA team. The preparation phase based on prototype cavities covered: qualification of potential vendors for material and cavity fabrication; work out recipe and strategy for qualification of the infrastructure for cavity surface treatment at industry; definition of the quality management strategy, documentation and electronically data exchange. Production of 800 series cavities on the principle “build to print” is contracted to companies Research Instruments and Ettore Zanon. High purity niobium and NbTi for resonators provides DESY. The principles of the material and cavities production in conformity with European Pressure Equipment Directive are developed together with the notified body. New or upgraded infrastructure has been established at both companies. The first several tens of series cavities have been produced and treated. Most of the cavities handed over to DESY up to now fulfill immediately the EXFEL specifications. The cavity production for EXFEL will be finished mid of 2015.
	Slides MOIOA03 [7.394 MB]

MOP039	Strategy of Technology Transfer of EXFEL Preparation Technology to Industry	197
	A. Matheisen, J. Iversen, A. Schmidt, W. Singer DESY, Hamburg, Germany P. Michelato, L. Monaco INFN/LASA, Segrate (MI), Italy
	For the EXFEL a specification for the cavitiy preparation procedures (R1)was set up and handed to the industrial companies. Basing on this specification companies hard ware as well as process flows were set up. Beside this specified part of the preparation technique the companies personal needed to be educated and the processes ramped up. To check the quality of the infrastructure, status of education of personal and correct set up of process flows, so called Dummy (DCV) - , Reference (RCV ) and Pre-series (PCV) cavities were assigned. We report on the general strategy applied for the EXFEL technology transfer on cavity preparation and the results obtained on the qualification cavities. R1) Series Surface and acceptance test preparation of superconducting cavities for the European Xfel (XFEL/A - D) JUNE 30, 2009

MOP040	Industrialization of European XFEL Preparation Cycle “Final EP ” at Research Instruments Company	201
	A. Matheisen, N. Krupka, M. Schalwat, A. Schmidt, M. Schmökel, W. Singer, B. van der Horst DESY, Hamburg, Germany P. Michelato, L. Monaco INFN/LASA, Segrate (MI), Italy M. Pekeler RI Research Instruments GmbH, Bergisch Gladbach, Germany
	In the Specification for XFEL Cavity preparation (R1) two different preparation sequences are presented. Research Instruments Company as one of the two companies contracted for XFEL cavity production and preparation has chosen the so called “final EP” cycle. Major infrastructure components like EP facility and the BCP facility were pre- qualified. This existing and the new set up areas like the cleanroom are distributed over the ground area of the industrial park Bergisch Gladbach. The process flow given in the DESY specification needed adaptation to this scenario. Additional infrastructure beside the once specified needed to be set up to ensure the same quality of processes even with a changed work flow. The general lay out of the facility, matched work flow of preparation and test results of resonators processed by RI company in their infrastructure will be reported. (R1) Series Surface and acceptance test preparation of superconducting cavities for the European Xfel (XFEL/A - D) JUNE 30, 2009

MOP042	Quality Control and Processes Optimization for the EXFEL Superconducting Cavities Series Production at Ettore Zanon spa	208
	L. Facci, D. Rizzetto Ettore Zanon S.p.A., Nuclear Division, Schio, Italy G. Corniani Ettore Zanon S.p.A., Schio, Italy A. Matheisen DESY, Hamburg, Germany P. Michelato, L. Monaco INFN/LASA, Segrate (MI), Italy
	The construction of the European XFEL forced the first mass production of Niobium bulk SRF cavities. In this context Ettore Zanon S.p.A. built a fully new facility designed to produce four fully treated and He tank equipped cavities per week, ready to be tested at DESY. The facility already reached the foreseen production rate. The guarantee of the highest quality of the resonators produced requires a very strict quality control plan. At the same time, the requirements of the industrial production in terms of time, cost and productivity must be satisfied. As a consequence processes must be standardized and working times optimized. In the following, after the description of the production facility, we would like to highlight and discuss the strategies and arrangements adopted in the various critical fields (clean room, vacuum, etc.) to ensure the foreseen results. Moreover correlation between cavities performances and production cycle parameters will be investigated and discussed.

MOP043	ILC-HiGrade Cavities as a Tool of Quality Control for European XFEL	212
	A. Navitski, E. Elsen, B. Foster, J. Iversen, A. Matheisen, D. Reschke, W. Singer, X. Singer, L. Steder, M. Wenskat DESY, Hamburg, Germany R. Laasch, Y. Tamashevich University of Hamburg, Hamburg, Germany
	Funding: BMBF, Helmholtz Association, ILC-HiGrade, FP7 (CRISP), Alexander von Humboldt Stiftung/Foundation The EXFEL order for SRF cavities includes 24 cavities, which are part of the ILC-HiGrade program. Initially, these cavities serve as quality control (QC) sample extracted from the EXFEL cavities series production on a regular basis. The QC and quality assurance (QA) include all processing steps of the EXFEL cavities. To maximize the information from these so-called QC cavities, a surface mapping technique is applied in a second cold RF test. There the cavities delivered have experienced identical treatment of the inner surface with the exception of mounting of the Helium vessel. After the normal acceptance test at the cavity RF measurement facility, the cavities are removed from the production flow. Further quality assurance steps beginning with a detailed RF test with surface mapping followed by a high resolution optical inspection (OBACHT) are carried out to improve the understanding of defects in close collaboration with the standing experts engaged in the EXFEL production. Results of the first QC cavities tests as well as planned further R&D will be presented and discussed.

MOP045	Electropolishing for EXFEL Cavities Production at Ettore Zanon SpA	220
	M. Rizzi Ettore Zanon S.p.A., Schio, Italy A. Gresele Ettore Zanon S.p.A., Nuclear Division, Schio, Italy A. Matheisen, N. Steinhau Kühl DESY, Hamburg, Germany P. Michelato INFN/LASA, Segrate (MI), Italy
	A new horizontal electropolishing (EP) facility has been implemented by Ettore Zanon SpA for the series production of the EXFEL cavities produced by the company. According to EXFEL specification a bulk EP of at least 100 micron is the first step of the surface treatment for high performances. Particular attention has been dedicated to find the best configuration during qualification of the system. Correlation between process variables, RF tests at room temperature at Zanon and vertical RF tests at 2 K at DESY have been investigated and the Niobium removal optimized. The facility has been designed for industrial scope, in order to guarantee the required quality and production rate of 4 cavities per week. One of the most important aspects has been the system automation to have complete control of the process.

MOP047	Set up of Production Line for EXFEL Beam Position Monitor and Quadrupol Units for Cavity String Assembly at CEA	224
	M. Schalwat, M. Koepke, A. Matheisen, H. Weitkämper DESY, Hamburg, Germany
	The super conducting (s.c.) accelerator models of the EXFEL consist of eight s.c. resonators, one s.c. quadrupol magnet and one beam position monitor. These components are connected inside ISO 4 cleanroom at CEA Saclay to a so called cavity string under the guidance of the XFEL WP 09 activities. The eight s.c. cavities are handed from DESY to CEA for string assembly after successful RF test. The beam- position monitor and Quadrupol units (BQU) are assembled and cleaned in the DESY cleanroom at DESY Hamburg to the same standard’s of cleanliness as requested for s.c. Cavities. The completed BQU units are handed over to CEA IRFU / WP 9 in “ready for installation to cavity string“ status. The setup of infrastructure, the qualification of processes and transport as well as the ramp up to a delivery rate of 1 BQU per week will be presented.

MOP048	PED Requirements Applied to the Cavity and Helium Tank Manufacturing	227
	A. Schmidt, J. Iversen, A. Matheisen, W. Singer DESY, Hamburg, Germany
	For the European XFEL more than 800 Cavities are manufactured by industrial partners. Each cavity is housed in an individual cryo vessel, the so called helium tank. All vessels are made from titanium and manufactured by industry as well. The cavity, welded into its helium tank, is a pressure loaded part and has to follow the pressure equipment directive - PED (97/23/EC). Setting up a series production of cavities and helium tanks by different vendors according given standards, was the task of the EXFEL WPG-1 LINAC-WP04. In cooperation with the TUEV-Nord as the notified body, DESY is responsible for the qualification of design, material in use and reasonable tests to get a certificate for pressure bearing parts.

MOP049	Progress and Experiences of Series Production of Helium Tanks With DESY as a Subcontractor for RI	231
	A. Schmidt, J.A. Dammann, A. Daniel, A. Matheisen DESY, Hamburg, Germany
	DESY acts as a subcontractor for helium tanks, for one of the cavity manufacturer in charge, for the EXFEL cavity production. Here the full responsibility of production, quality and warranty of these parts is at DESY. Therefore on 400 out of the total of 800 helium tanks, DESY has to set up a logistic of incoming inspection, documentation, storage and distribution. Special effort is made to archive a free of doubts interconnection and integration of the cavity into the helium tank. After more than 300 units produced a review and statistic is provided.

TUP056	Industrialization of European XFEL Preparation Cycle “BCP Flash” at Ettore Zanon Company	547
	A. Matheisen, N. Krupka, M. Schalwat, A. Schmidt, W. Singer, N. Steinhau Kühl, B. van der Horst DESY, Hamburg, Germany G. Corniani Ettore Zanon S.p.A., Schio, Italy P. Michelato, L. Monaco INFN/LASA, Segrate (MI), Italy
	In the Specification for XFEL Cavity preparation (R1) two different preparation sequences are presented. Ettore Zanon Company as one of the two companies contracted for XFEL cavity production and preparation has chosen the so called BCP flash cycle. To fulfill the requested work flow and quality of infrastructure and processes, the company set up a complete new infrastructure in refurbished fabrication halls. The layout of the facility, set up of work flow of preparation and test results of resonators processed by E.Zanon in their infrastructure will be reported. (R1) Series Surface and acceptance test preparation of superconducting cavities for the European Xfel (XFEL/A - D) JUNE 30, 2009

TUP094	Influence of Heat Treatments on Field Emitters on Nb Crystals	690
	S. Lagotzky, G. Müller Bergische Universität Wuppertal, Wuppertal, Germany A. Matheisen, D. Reschke DESY, Hamburg, Germany
	Funding: Funding by HGF Alliance and the BMBF project 05H12PX6 Systematic investigations of the enhanced field emission (EFE) of HPR-cleaned large grain (LG) and single crystal (SC) Nb samples (Ra < 0.5μm) revealed an exponential increase of the emitter number density N with electric surface field Es and strong activation effects of the remaining particulates. Different types of EFE activation were observed: by high E partially combined with a micro-discharge or by heat treatments (HT) [1]. In cavities, EFE activation might also occur due to enhanced rf losses of particulates. Therefore, we have started a test series with two LG and two SC typically prepared Nb samples (40 μm BCP, 140 μm EP and HPR at DESY). At first all emitters (1 nA) up to Es = 160 MV/m were localized by means of correlated field emission microscopy (FESM). Then systematically varied in-situ HT between 122°C (24 h) and 400°C (2 h) were applied to investigate the activation of emitters due to the change of the natural Nb oxide. For all samples a significant increase of N with stronger HT up to 32 emitters/cm² at 400°C were obtained resulting in some activated emitters already at Es = 40 MV/m. Final SEM images of the activated emitters will also be discussed. [1] A. Navitski et. al, subm. to PRSTAB 2013