ILC R&D at Fermilab Robert Kephart. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review2 Outline Fermilab ILC Goals Fermilab’s role in the GDE

ILC R&D at Fermilab

Robert Kephart

May 15-18, 2006 FY06 DOE Annual Review 2

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Outline

• Fermilab ILC Goals• Fermilab’s role in the GDE & the ILC machine Design• Main Linac design

– Accelerator physics – Main Linac components (Cryomodule, RF components)

• SCRF Cavity & Cryomodule R&D – Cavity R&D – 3.9 GHz and 1.3 GHz Collaboration with DESY– ILC Cryomodule Design

• RF activities ( Modulators, Klystrons, LLRF & Controls)• SCRF infrastructure

– FNAL/ANL joint facility for cavity BCP and EP– Cryomodule assembly Facility – ILC test facilities (ILCTA)

• ILC Civil and Site Development• Industrialization• Funding• Conclusion


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Goals of Fermilab’s ILC R&D

• The overarching goal of Fermilab’s ILC R&D program is to establish credentials in machine design and SCRF technology such that FNAL is the preferred international site to host the ILC.

As part of the Global Design Effort (GDE) our goal is to help design the machine, estimate the cost, and gain international support.

• Fermilab ILC R&D activities: – ILC Machine Design – Development of SCRF technology & infrastructure– Conventional Facility & Site Studies for a US ILC site – Industrialization & Cost Reduction– ILC Physics, Detector Design, and Detector R&D


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fFermilabFermilab’s Role in the GDE

• GDE goal = complete the Reference Design Report (RDR) and a cost estimate by the end 2006 established RDR organization

• Design & Cost Board (coordinates machine design)– Responsible for producing the RDR and the cost estimate– 9 members ( 3/region) + Chairman– P Garbincius ( FNAL) = chair, R. Kephart (FNAL) member

• Change Control Board (ILC baseline configuration control) – 9 member board (3/region), N Toge = Chairman– S. Mishra (FNAL) is one of 3 U.S. Members

• ILC Machine “Area” Leaders (typically 3 Ldrs 1/region)– Civil and Site: Vic Kuchler (FNAL) = Americas Ldr– Main Linac Design: N. Solyak (FNAL) = 1 of 2 Americas Ldrs– Cryomodule: H. Carter (FNAL) = Americas Ldr– Cryogenics system: T. Peterson (FNAL) = Americas Ldr– Magnet systems: J. Tompkins (FNAL) = Americas Ldr – Communications: E. Clements (FNAL) = Americas Ldr

• FNAL is playing a major role in the GDE & ILC machine design


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ILC Machine Design

• Fermilab has focused its R&D efforts on the ILC Main Linacs.

• Main Linac activities:– Accelerator physics design

– Demonstrate feasibility of all Main Linac technical components

– Engineering design of ML technical systems

– Estimates of the ML cost & methods for cost reduction

– U.S. Industrialization of high volume ML components• Other R&D ( smaller efforts)

– Design studies of the ILC Damping Rings – Working on the Machine-Detector Interface– Physics studies & Detector R&D

• Civil and Site Development activities:– Civil engineering of machine enclosures

– With the GDE, develop a matrix for comparing possible ILC sites

– Study U.S. sites on or near the Fermilab site


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• Accelerator physics: – Main Linac optics studies – End-to-end simulation of the machine – Study emittance preservation and vibration issues– RF timing and control issues

• Engineering Design of Main Linac components– Fermilab has been asked to supply lots of engineering

in FY06 in support of the Main Linac design for the RDR– Cryomodule Development (incl. high gradient cavities!)– Cryogenic & RF system Design– LLRF & control systems design– Design of linac auxilary systems

• In April of 2006 FNAL had 120 FTE working on ILC R&D or on developing lab SCRF expertise

Main Linac Design


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SCRF Cavity R&D

• Our goal is to rapidly advance the intellectual understanding of SCRF surface physics and establish process controls to reliably achieve high gradient ( 35 MV/M) SCRF cavity operation

• Approach: Establish a “tight loop” processing and test infrastructure in the U.S.

• Tight loop elements:– Cavity fabrication improvements ( e.g. large grain Nb)– BCP & Electro-polish facilities– High purity water and High pressure rinse– Vertical test facilities– SCRF experts & materials program to interpret results

• SCRF materials program =FNAL,UW,NW,Cornell,TJNL,MSU, etc


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ILC 1.3 GHz Cavities @ FNAL

• Industrial fabrication of cavities, some in U.S. Industry• Two Single/large Crystal cavities under development with TJNL• BCP and vertical testing at Cornell (25 MV/m) (17 MV/m 1st try)• Next … EP and vertical testing at TJNL. ( 35 MV/m)• Joint BCP/EP facility being developed ANL (2007)• High Power Horizontal test facilities @ FNAL (2006)• Vertical test facility @ FNAL (2007)• More later on these facilities

4 cavities received from ACCEL4 cavities on order at AES2 cavities on order at TJNL

BCP and Vert Test at Cornell


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DESY Collaboration

• Fermilab and DESY have collaborated on advanced accelerator R&D for many years

• As members of the TESLA collaboration: – FNAL & DESY collaborated to build both TTF & the Fermilab

NICADD Photo-Injector Lab (FNPL) at A0– Currently FNAL is building a 3.9 GHz 3rd Harmonic module for

the TTF @ DESY (doubles light output of the VUV-FEL)

• Status of the 3.9 GHz effort– 3.9 GHz cryomodule design is complete– Uses four 9 cell 3.9 GHz cavities ( 2 of 6 total are now welded)– BCP processing at joint ANL/FNAL facility in FY06– Vertical test @ A0, Horizontal test in ILCTA_MDB

• Serving as a pilot program for much of our ILC SCRF infrastructure (processing, vertical and horizontal test, cryomodule assembly, etc.)

• Expect to deliver the 3.9 GHz module to DESY in early 2007


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DESY Collaboration

3.9 GHz

9 cell 3.9 GHz cavity


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DESY Collaboration

• DESY and INFN will supply Fermilab with all the parts for one 1.3 GHz (type 3) TESLA cryomodule– DESY will send us 8 TESLA 9 cell cavities– Vertically tested, dressed, & horizontally tested @DESY– Goal is to qualify them to 28 MV/M– DESY will also supply cold mass parts– Expect all parts at FNAL early in FY07

• Will be the 1st ILC type cryomodule built in the U.S.• Plan to assemble it by summer of 2007• Then… test it at Fermilab later that year


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ILC Cryomodule

• ILC Cryomodule Design– Collaborative effort on the next generation ILC cryomodule

• 1st ILC Cryomodule (2006-07)– Assemble a TESLA TTF type III cryomodule from the “kit”

of part provided by DESY, cavities fully tested.

• 2nd Cryomodule (2007-08)– Also TTF type III cryomodule– Uses cavities that are processed and tested in the US

• Cavities: Accel(4), AES(4), TJNL(2)• Cryostat and cold mass from Zannon in Europe

– BCP processing at JLAB & Cornell– Electropolish at JLAB and perhaps ANL/FNAL joint facility– Vertical test (bare) at Cornell & JLAB – Horizontal test (high power) at FNAL ILCTA_MDB


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ILC Cryomodule

• 3rd-4th Cryomodules (2008-09)– 1st type IV cryomodules built anywhere– Begin industrial production of components– Assembly and test at Fermilab

• 5th-6th Cryomodules (2010)– Transfer knowledge gained to Industry for ILC cryomodule

mass production

• 2006-2010: Develop, build & test basic building blocks of the Main Linac– Cryomodules (including cavities, couplers,

instrumentation, etc)– RF systems ( modulators, klystrons, LLRF)– Cryogenic system design

• Evaluate main linac cost and reliability issues


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Cryomodule

• ILC cryomodules are complex objects• TTF cryomodules (type III) need to evolve for ILC• FNAL is collaborating with DESY, INFN, KEK,

CERN, JLAB, SLAC, etc. on the design of the next generation ILC cryomodule (Type IV)

DESY TTF

ILC cryomodule


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Main Coupler & Tuner R&D

TESLA Blade-Tuner

Fermilab is also working on controlling Lorentz detuning via Piezoelectric tuners in a feed-forward system

TESLA Main Coupler

1.3 GHz, pulsed operationTwo windows, adjustable2K (4K) heat load 0.06 (0.5) W

Main Couplers and tuners are complexFNAL plans R&D aimed at cost reduction


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ILC RF Systems R&D

• Modulator R&D

– 10 Modulators built based on Fermilab design

– 3 by FNAL and 7 by industry– In operation ~10 yrs @ DESY and FNPL – 2 new Modulators will be finished in FY06 – 1 = PD, other = ILC, collaborating with

SLAC • Klystrons

– Design improvements are needed to reach reliable long-term operation at 10 MW peak / 150 kW average power.

– Also need to develop U.S. vendors– SLAC will supply a new 10 MW klystron

• LLRF R&D in collab Penn, DESY, INFN, etc.

FNPL Modulator

10 MW Thales Klystron


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ILC RF Systems R&D

• Overall objective is to assemble one, then two ILC RF units in New Muon building ( ILCTA_NM) 1st by about 2009, 2nd a year or so later– Two x 3 Cryomodules– Two Modulators– Two 10 MW Klystrons– Waveguide and RF distribution components– LLRF & controls– Move FNPL photo injector to provide electron beams

• Other RF tasks– 3.9 GHz RF power and LLRF for tests– Small RF systems for Vertical & Horizontal test facilities– Industrialization of RF components (more in a minute)


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• Following the technology choice in Aug 04 FNAL launched a major program to develop the extensive SCRF infrastructure required for ILC– ILC/GDE specific R&D tasks described in an MOU– FNAL is also spending “lab” operating funds on this

• The required infrastructure is complex– It takes time to develop– It takes time to train personnel to achieve cavities with

high operating gradients– It is expensive! DESY spent >125 M euro M&S on TTF

and the associated infrastructure

• Costs are “front loaded” but our funding is not • Our ability to make progress is funding limited

SCRF infrastructure


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SCRF Infrastructure

• High gradient cavities require extensive infrastructure• Bare cavities

– Fabrication facilities ( e.g. Electron beam welders) – Buffered Chemical Polish facilities (BCP)– Electro-polish facilities (EP)– Ultra clean H20 & High Pressure Rinse systems– Vertical Test facilities ( Cryogenics + low power RF)

• Cavity Dressing Facilities ( cryostat, tuner, coupler)– Class 100 clean room– Horizontal cavity & Coupler test facility ( RF pulsed power)

• String Assembly Facilities– Large class 100 clean rooms, Large fixtures– Class 10 enclosures for cavity inner connects

• Cryo-module test facilities– Cryogenics, pulsed RF power, LLRF, controls, shielding, etc.– Beam tests electron source (e.g. FNPL Photo-injector)

• FNAL and U.S. collaborators are building this $$$$$


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TJNL e-beam welding

Chemistry

TJNL Electro polish

Horizontal Test ofDressed Cavity @ DESY

Examples: SCRF infrastructure

Cryomodule Test at DESY TTF


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The inter-cavity connection is done in class 10 cleanroom

Examples: Cryomodule Assembly

Assembly of a cavity string in a Class 100 clean room at DESY

Cryomodule Assemby at DESY

Lots of new specialized SCRF infrastructure needed for ILC!


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Building U.S. SCRF infrastructure

• Existing U.S. facilities at Cornell, TJNL, and ANL are being upgraded to process the 1.3 GHz ILC cavities but not sufficient

• A new FNAL/ANL BCP facility built at ANL (operational late 2006)

• An Electro-polishing facility is being designed by the ILC Collaboration

• A prototype will be built at ANL/Fermilab Cavity Processing Facility at ANL.


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FNAL SCRF Infrastructure

CAF-MP9

Large Class-100 clean room

Installed & Passed certification

•A Cryomodule Assembly Facility (CAF) is being built in (MP9)•Vertically tested cavities will be dressed (He vessel, coupler, etc) in smaller clean rooms prior to horizontal test•Horizontally tested cavities assembled into a string in large clean room before final Cryo-module assembly takes place

Parts for new Cryomodule

Assembly fixture in IB4

Plan = expand CAF into Industrial Center Bldg after LHC quads


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ILC Test Areas (ILCTA)

• SCRF test facilities are needed to carryout the ILC program• Vertical Test (bare cavities) IB1

– IB1 has 60 W @ 1.8 K now

– Ordered dewar, civil in progress

• Horizontal Test (dressed cavities)– IB1 & Meson Bldg (PD)

– Meson will have 60 W @ 1.8 K soon

• Cryomodule test facility– Contract to remove CCM

– installing cryogenics

– Photo injector moves e beam

– Power 1st cryomodule in 2007

• RF Power & Cryogenics These are Big expensive facilities !

Industrial Building 1

New Muon Lab


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Civil and Site Development

• Goal: Determine the best possible site for an ILC in Illinois• With the GDE we are developing the ILC Civil Design

– Tunnel Design ( diameter, # shafts, laser-straight vs curved

• Site specific machine and Civil design will start in FY07– Geological, environmental, community impact studies

not to scale~30

km

x2R = 955mE = 5 GeV

ML ~10km (G = 31.5MV/m)

3.2 m

5.5 m 4.5 m

not to scale

RDR

FNAL site


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Industrialization

• The principle goal of ILC industrialization is to establish in US industry the capability and infrastructure to mass produce the components to build the ILC

• Another important goal is cost reduction

• Cryomodules (2000 required for 500 GeV of linac)• SCRF Cavities: (16,000)

– Reliably achieve > 35 MV/m and Q ~1x1010

• RF couplers and Cavity Tuners (16,000 each)• RF Components

– ~ 650 klystrons ( 1.3 GHz, 10 MW, 1.5 ms, 5 Hz)

– ~ 650 modulators

– Waveguide, circulators, host of other RF and vacuum components…


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Industrialization

• Large Cryogenic systems (~ 40 KW at 1.8 K) • Detectors, instrumentation, etc…• Civil construction

– A huge job ( currently estimated @ 40% of the ILC cost)

• In FY06 the GDE plans Industrial cost estimates– Limited in scope ( available funding is small)

• US industrialization for ILC is just beginning– FNAL helped create an Industrial Forum in 2005

– Industrial involvement in cost estimates has started

– Need industrial studies aimed at cost reduction

– Need industry to build things !

• Our ability to engage U.S. industry is limited by the available funding

• Hope is that FY07 funding will allow a sensible start


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Systems Tests

• It is Fermilab’s opinion that a significant systems test will be required in advance of ILC construction to verify:– Technical performance of critical/cost driving components

– Systems integration

– Vendor performance

– Reliability of cost estimate

• Should include ~1% of final cryomodule count, produced by vendors in a pre-production run– Plan is to assemble into ~ 5 GeV electron linac

– Mount in a near surface twin tunnel ILC mock up

– Could include a demonstration damping ring in Tev Tunnel

• We propose to host this facility at Fermilab • Believe the correct approach is to develop requirements

first, then evaluate possible facilities.– Discussion with the GDE are in progress


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ILC and SCRF Resources

• FY06: FNAL program was scaled back to fit budget.• FY07 represents Fermilab desires (actually->186 FTE)• Bid-to-host funds mostly go to outside A&E firms

Numbers are direct no overhead


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Conclusions

• Fermilab has a large and growing ILC R&D effort• Our prime objective is to achieve technical excellence in

the Main Linac systems and to position ourselves to be a strong candidate to host the ILC

• We work closely with international partners in the GDE on the machine design– Main Linac ( accelerator physics, simulation )– Civil & Site studies– Accelerator systems( cryogenics, RF, controls, etc) – Small efforts on electron source, damping rings

• We are building an extensive SCRF infrastructure and developing expertise in support of these goals– High gradient cavities (design, fabrication, BCP, EP )– Cryomodule Design & Assemby ( CAF)– Cavity test facilities ( horizontal and vertical)– Cryomodule Test facilities ( ILCTA including beam tests )

• Our progress is limited by the available funding

Documents

ILC R&D at Fermilab Robert Kephart. ILC Americas f Fermilab May 15-18, 2006FY06 DOE Annual Review2 Outline Fermilab ILC Goals Fermilab’s role in the GDE