Tfir Cavity Welding

EBW Weld preparation and Weld Gap Detection Hot Topic SRF 2011 By Ralf Edinger, PAVAC July 28, 2011, Chicago 02/22/2020 2004 2009 PAVAC Industries Inc. All rights reserved 1 Introduction PAVAC Industries Industries Inc. Inc. PAVAC 12371 Horseshoe Horseshoe Way, Way, Unit Unit 12371 105 105 Richmond, BC BC Richmond, V7A 4X6, 4X6, Canada Canada V7A Phone 11 (604) (604) 231 231 0014 0014 Phone Fax 11 (604) (604) 326 326 9078 9078 Fax PAVAC produces Electron Beam Machines (EBW,

EB-PVD...) and fabricates SRF cavities. Electron Beam Beam Electron SRF-Cavities SRF-Cavities PAVAC Energy Energy Corp. Corp. PAVAC 204 S. S. Water Water Street Street 204 Batavia, IL, IL, Batavia, 60510, USA USA 60510, Phone 11 (630) (630) 326 326 9012 9012 Phone Fax 11 (630) (630) 326 326 9078 9078 Fax 02/22/2020 2004 2011 PAVAC Industries Inc. All rights reserved 2 EBW Start at defining fabrication tolerances

Should allow test assembly before pre-weld etching, but minimizes the weld gap Weld edge after pre-weld etch Difficulty assembling etch parts Geometric dimensioning and tolerance (GD&T) Costs related to tolerances 0.02mm 0.05mm 0.1mm Weld Gap detection Positioning and contour accuracy during EBW 02/22/2020 2004 2009 PAVAC Industries Inc. All rights reserved 3 Conclusion to weld geometry EBW requires to design a weld geometry which allows better melting of RRR Nb and NbTi. The proposed changes can be achieved with existing material selection. Step in Beam tube min 0.8mm; can be achieved without changing the 3mm RRR Nb Sheet 3mm 02/22/2020 2004 2009 PAVAC Industries Inc. All rights reserved 4 Weld Gap Detection CCD Camera Camera ++ Machine Machine CCD Vision

Vision Reflective Electrons Electrons Reflective Under Development Development Under X-Ray Detection Detection X-Ray e Machine Vision Vision System System takes takes Machine real time time CCD CCD images images and and real processes data data and and displays displays processes key information information for for user. user. key Seam tracker tracker (electron (electron trap) trap) Seam mounted isolated

isolated in in chamber chamber mounted Software analysis analysis the the returned returned Software electrons and and finds finds the the gap. gap. electrons X-Ray CCD X-Rays from from electron electron beam beam X-Rays show structural structural changes changes on on show X- ray ray chip chip below below weld weld Xparts. XX- ray ray image image (array) (array) parts. transferred to to Machine Machine transferred

Vision software software for for Vision processing. processing. 5 2004 2011 PAVAC Industries Inc. All rights reserved Accuracy and Repeatability Linear Scales 02/22/2020 2004 2011 PAVAC Industries Inc. All rights reserved PAVAC uses uses AC AC linear linear motors motors PAVAC combined with with linear linear scales. scales. Linear Linear combined motors have have no no contact contact and, and, motors therefore, lubrication lubrication is is not not therefore, required. required.

Linear scales scales have have aa resolution resolution of of Linear 0.001mm and and allow allow aa repeatability repeatability 0.001mm of less less than than 0.005mm. 0.005mm. of The increased increased machine machine accuracy accuracy The allows aa better better positioning positioning of of the the allows beam for for welding. welding. beam In order order to to form form aa consistent consistent under under In bead in in cavity cavity areas, areas, the the beam

beam bead requires aa positioning positioning accuracy accuracy of of requires plus/ minus minus 0.025mm. 0.025mm. Therefore Therefore plus/ the machine machine requires requires for for control control the purposes aa 10 10 times times higher higher purposes process resolution, resolution, which which is is process 0.0025mm. 0.0025mm. 6 Vacuum Inside Cavity Smart fixtures for better alignment and faster weld assembly Vacuum pressure inside the cavity during weld procedures requires optimal tool design 02/22/2020 2004 2011 PAVAC Industries Inc. All rights reserved

7 EBW & Fixture BEAM - ARRANGEMENT TYPE 1 TYPE 2 TYPE 3 EBW fixture to secure half cell close to equator during welding. Integrated dynamic weld preload (springs) for length compensation. Effect: Colder surfaces (steeper T) reduces adhesive bonding of weld deposition. 02/22/2020 2004 2009 PAVAC Industries Inc. All rights reserved 8 End Cell Fabrication EBW-Medium Chamber for Aerospace Sensors Design for end-cell production Pump down to weld pressure 30 seconds Single (simple) task tooling and process controls Changing setup is easy Operation entry user level 02/22/2020 2004 2011 PAVAC Industries Inc. All rights reserved 9

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