SRF2013 - List of Authors (Michelato, P.)

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]

MOP011

European XFEL 3.9 GHz System

100

P. Pierini, M. Bertucci, A. Bosotti, C. Maiano, P. Michelato, L. Monaco, R. Paparella, D. Sertore
INFN/LASA, Segrate (MI), Italy
C. Pagani
Università degli Studi di Milano & INFN, Segrate, Italy
E. Vogel
DESY, Hamburg, Germany

The third harmonic system of the European XFEL is a joint INFN and DESY contribution to the project. Achievements, status and activity plan will be reviewed.

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.

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.

TUP035

Neutron Activation Analysis as a Foreign Intrusion Cavity DetectionTool

495

C. Maiano, P. Michelato
INFN/LASA, Segrate (MI), Italy
M. Clemenza
Universita Milano Bicocca, MILANO, Italy
C. Pagani
Università degli Studi di Milano & INFN, Segrate, Italy

Neutron Activation Analysis (NAA) is one of the currently available techniques used to determine contaminants in Nb superconducting cavities, allowing a non-destructive determination of foreign materials, provided they have radioactive isotopes with a sufficiently long half-life. We present the NAA technique application with the goal of contaminants determination, identification and localization for the European XFEL 3rd harmonic cavities (3.9 GHz). Irradiation and analysis has been performed in collaboration with the LENA nuclear reactor (Pavia, Italy) and the University of Milano Bicocca. The main difference respect to the measurements performed in the past is the goal to apply of the NNA directly to entire cavities and not to material samples. Currently nine samples were exposed to thermal and fast neutron flux and the resulting activity was measured with HPGe detectors.

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

TUP062

Application of In-Vacuum Infrared Pyrometry During Fabrication of European XFEL Niobium Cavities

570

L. Monaco, P. Michelato, D. Sertore
INFN/LASA, Segrate (MI), Italy
V. Battista, G. Corniani, M. Festa
Ettore Zanon S.p.A., Schio, Italy
C. Pagani
Università degli Studi di Milano & INFN, Segrate, Italy

A technique to measure the temperature of Niobium components in vacuum during Electron Beam Welding (EBW) operation is presented and results obtained on the large scale cavity production for the European XFEL are discussed. During the EBW process, the knowledge of the components temperature during the welding operation could help both for the better choice of the welding parameters and for the optimization of the production cycle. In collaboration with the Italian firm Ettore Zanon (EZ), we developed a system able to measure the temperature of Nb components in vacuum during EBW operation using a IR pyrometer placed outside the vacuum chamber through an appropriate vacuum viewport. In the paper the experience of this device during the production of Nb components for the XFEL 1.3 GHz cavity production is discussed.

TUP102

Quench Detection Diagnostics on 3.9 GHz XFEL Cavities

710

M. Bertucci, A. Bosotti, L. Garolfi, P. Michelato, L. Monaco, D. Sertore
INFN/LASA, Segrate (MI), Italy
C. Pagani
Università degli Studi di Milano & INFN, Segrate, Italy

This paper presents results of quench localization on 3.9 GHz XFEL prototype cavities tested at LASA vertical test facility. Cavities have been equipped with OST second sound detectors and thermometry sensors. A first guess for quench position has been obtained from modal analysis. Second sound sensors confirmed the quench position resolving also the symmetry degeneracy given by the RF mode pattern analysis. In a subsequent vertical test, second sound and temperature sensors have been installed nearby the suspect quench position. From Thermometry mapping, a sudden increase in cavity temperature within a small region is evident, therefore confirming that a local thermal breakdown due to defect heating occurs in the predicted quench point. The quench region deduced with the mentioned techniques is eventually compared with results of optical inspection.

TUP110

An X-Ray Fluorescence Probe for Defect Detection in Superconducting 1.3 GHz Cavities

736

P. Michelato, M. Bertucci
INFN/LASA, Segrate (MI), Italy
A. Navitski, W. Singer, X. Singer
DESY, Hamburg, Germany
C. Pagani
Università degli Studi di Milano & INFN, Segrate, Italy
Y. Tamashevich
Uni HH, Hamburg, Germany

The aim of this project is to develop a system for defect detection by means of X-ray fluorescence (XRF) analysis. XRF is a high sensitivity spectroscopy technique allowing the detection of trace element content, such as the few microgram impurities, responsible for low cavity performances if embedded in the equatorial region during cavity manufacturing. The proposed setup is customized on 1.3 GHz TESLA-type niobium cavities: both the detector and the X-ray excitation source are miniaturized so to allow the probe to enter within the 70 mm iris diameter and aside of the HOM couplers. The detection-excitation geometry is focused on cavity cell equator surface located at about 10³ mm from the cavity axis, with an intrinsic spot-size of about 10 mm. The measuring head will be settled on a high angular resolution optical inspection system at DESY, exploiting the experience of OBACHT. Defect position is obtained by means of angular inner cavity surface scanning. A quantitative determination of defect content can also be carried out by means of fundamental parameters technique with a Niobium standard calibration.

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]

MOP011	European XFEL 3.9 GHz System	100
	P. Pierini, M. Bertucci, A. Bosotti, C. Maiano, P. Michelato, L. Monaco, R. Paparella, D. Sertore INFN/LASA, Segrate (MI), Italy C. Pagani Università degli Studi di Milano & INFN, Segrate, Italy E. Vogel DESY, Hamburg, Germany
	The third harmonic system of the European XFEL is a joint INFN and DESY contribution to the project. Achievements, status and activity plan will be reviewed.

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.

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.

TUP035	Neutron Activation Analysis as a Foreign Intrusion Cavity DetectionTool	495
	C. Maiano, P. Michelato INFN/LASA, Segrate (MI), Italy M. Clemenza Universita Milano Bicocca, MILANO, Italy C. Pagani Università degli Studi di Milano & INFN, Segrate, Italy
	Neutron Activation Analysis (NAA) is one of the currently available techniques used to determine contaminants in Nb superconducting cavities, allowing a non-destructive determination of foreign materials, provided they have radioactive isotopes with a sufficiently long half-life. We present the NAA technique application with the goal of contaminants determination, identification and localization for the European XFEL 3rd harmonic cavities (3.9 GHz). Irradiation and analysis has been performed in collaboration with the LENA nuclear reactor (Pavia, Italy) and the University of Milano Bicocca. The main difference respect to the measurements performed in the past is the goal to apply of the NNA directly to entire cavities and not to material samples. Currently nine samples were exposed to thermal and fast neutron flux and the resulting activity was measured with HPGe detectors.

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

TUP062	Application of In-Vacuum Infrared Pyrometry During Fabrication of European XFEL Niobium Cavities	570
	L. Monaco, P. Michelato, D. Sertore INFN/LASA, Segrate (MI), Italy V. Battista, G. Corniani, M. Festa Ettore Zanon S.p.A., Schio, Italy C. Pagani Università degli Studi di Milano & INFN, Segrate, Italy
	A technique to measure the temperature of Niobium components in vacuum during Electron Beam Welding (EBW) operation is presented and results obtained on the large scale cavity production for the European XFEL are discussed. During the EBW process, the knowledge of the components temperature during the welding operation could help both for the better choice of the welding parameters and for the optimization of the production cycle. In collaboration with the Italian firm Ettore Zanon (EZ), we developed a system able to measure the temperature of Nb components in vacuum during EBW operation using a IR pyrometer placed outside the vacuum chamber through an appropriate vacuum viewport. In the paper the experience of this device during the production of Nb components for the XFEL 1.3 GHz cavity production is discussed.

TUP102	Quench Detection Diagnostics on 3.9 GHz XFEL Cavities	710
	M. Bertucci, A. Bosotti, L. Garolfi, P. Michelato, L. Monaco, D. Sertore INFN/LASA, Segrate (MI), Italy C. Pagani Università degli Studi di Milano & INFN, Segrate, Italy
	This paper presents results of quench localization on 3.9 GHz XFEL prototype cavities tested at LASA vertical test facility. Cavities have been equipped with OST second sound detectors and thermometry sensors. A first guess for quench position has been obtained from modal analysis. Second sound sensors confirmed the quench position resolving also the symmetry degeneracy given by the RF mode pattern analysis. In a subsequent vertical test, second sound and temperature sensors have been installed nearby the suspect quench position. From Thermometry mapping, a sudden increase in cavity temperature within a small region is evident, therefore confirming that a local thermal breakdown due to defect heating occurs in the predicted quench point. The quench region deduced with the mentioned techniques is eventually compared with results of optical inspection.

TUP110	An X-Ray Fluorescence Probe for Defect Detection in Superconducting 1.3 GHz Cavities	736
	P. Michelato, M. Bertucci INFN/LASA, Segrate (MI), Italy A. Navitski, W. Singer, X. Singer DESY, Hamburg, Germany C. Pagani Università degli Studi di Milano & INFN, Segrate, Italy Y. Tamashevich Uni HH, Hamburg, Germany
	The aim of this project is to develop a system for defect detection by means of X-ray fluorescence (XRF) analysis. XRF is a high sensitivity spectroscopy technique allowing the detection of trace element content, such as the few microgram impurities, responsible for low cavity performances if embedded in the equatorial region during cavity manufacturing. The proposed setup is customized on 1.3 GHz TESLA-type niobium cavities: both the detector and the X-ray excitation source are miniaturized so to allow the probe to enter within the 70 mm iris diameter and aside of the HOM couplers. The detection-excitation geometry is focused on cavity cell equator surface located at about 10³ mm from the cavity axis, with an intrinsic spot-size of about 10 mm. The measuring head will be settled on a high angular resolution optical inspection system at DESY, exploiting the experience of OBACHT. Defect position is obtained by means of angular inner cavity surface scanning. A quantitative determination of defect content can also be carried out by means of fundamental parameters technique with a Niobium standard calibration.