1 Conceptual Design of the New D1 Magnet by using Nb-Ti LHC Dipole Cable and Nb3Sn Cable Q. Xu, T. Nakamoto, E. Todesco Abstract—The development of a large-aperture (130-150 mm) dipole magnet is proposed in the framework of the CERN-KEK cooperation program. The application target is the D1 magnet (separation dipoles) replacement for the HL-LHC (High Luminosity - Large Hadron Collider) upgrade. The Cos-theta type coil cross section is adopted in the conceptual design of this magnet. The nominal field is 6 ~ 7 T at 1.9 K with a 30-mm-width coil arranged in two layers. The candidates of superconductor are Nb-Ti and bronze route Nb3Sn. The Nb-Ti LHC dipole cable (inner) is the baseline for the coil winding. We present the key parameters and the magnetic simulation of this magnet including the field quality in the aperture, the effect of iron saturation and filament magnetization and the stray field with iron cryostat. Index Terms— Superconducting accelerator magnets, Largeaperture, Cos-theta type coil, LHC dipole cable. with the current LHC dipole magnets. This makes stray field a critical aspect of the design. II. ANALYTICAL ESTIMATION OF THE MAGNETIC FIELD The critical current density (Jc) of the superconductors Nb-Ti and bronze route Nb3Sn can be fitted by using simple functions in Table I [3, 4]. The fitting error is within 5% on a wide domain. Fig. 1 shows the fit lines of these superconductors. The central magnetic field of a Nb-Ti dipole magnet at the short sample limit Bss can be expressed as a function of the aperture radius r, the equivalent coil width weq, the critical current density of the superconductor and the geometry parameters of the cable and of the coil without iron. This function is based on a simple sector coil model [3] 4500 Q. Xu, T. Nakamoto are with the High Energy Accelerator Research Organization (KEK), Tsukuba, Japan (e-mail: qingjin.xu@kek.jp). E. Todesco is with the European Organization for Nuclear Research (CERN), Geneva, Switzerland (e-mail: Ezio.Todesco @cern.ch). Non-Cu Jc (A/mm2) H L-LHC (High Luminosity-Large Hadron Collider) is an upgrade project of the current LHC. The main objective is to implement a hardware configuration and a set of beam parameters that will allow LHC to reach a peak luminosity of 5 × 1034 cm-2s-1 and an integrated luminosity of 250 fb-1 per year, which is ten times more than the integrated luminosity of the first 10 years of the LHC lifetime [1]. The conventional room-temperature magnet modules D1 (separation dipoles) are considered to be replaced by large-aperture radiation-hard superconducting magnets. The nominal field of the current D1 magnet is 1.28 T [2]. The new superconducting D1 magnet will increase the nominal field to above 6 T with an aperture diameter of 130-150 mm. The integrated field is also increased from 26 T m to 40 T m. The candidates of superconductor are Nb-Ti and bronze route Nb3Sn. The Nb-Ti LHC dipole cable (inner) is the baseline for the coil winding. If necessary, the higher Critical temperature of bronze route Nb3Sn is expected to provide more enthalpy margin than Nb-Ti to against the heat deposition by irradiation. In this report we present a preliminary analysis of the magnetic design: First we address the margin issue and then we estimate the expected nominal field for the two conductors for apertures ranging from 130 to 150 mm. We analyzed the effect of iron saturation and filament magnetization on the field quality and the stray field including the influence of iron cryostat. The outer diameter of the magnet is 570 mm, same NbTi 1.9K NbTi 4.2K Bronze Nb3Sn 1.9K Bronze Nb3Sn 4.2K ITER TF strand 4000 I. INTRODUCTION 3500 3000 2500 2000 1500 1000 500 0 6 7 8 9 10 11 12 13 14 15 Magnetic field (T) Fig 1: Jc fit of the superconductors by using the functions in Table 1. TABLE I: FITTING FUNCTION OF THE SUPERCONDUCTORS Superconductor Bronze Nb3Sn @ 4.2K Bronze Nb3Sn @ 1.9K NbTi @ 4.2K NbTi @ 1.9K Fitting function B c b jc c 1 B 21 1.0E+09 23.1 10 13 1.1E+09 6.0E+08 6.0E+08 jc c(b B) Bss Error 5% for 10-12 T * * Comparing with data from Hitachi cable 5% for 5-10 T [4] 5% for 6-13 T [4] kcb 0 weq 1 kc 0 ( weq ar ) (1) where k is the filling factor of the coil pack: k = kw-ckc-i/(1+vcu-sc); kw-c is the area ratio of strands to conductor (cable), kc-i is the area ratio of bare conductor to insulated conductor, and vcu-sc is the Cu/Non-Cu ratio of the strand; c and b are parameters of Jc fit in Table 1, γ0 is the central field per 2 unit of current density and unit of coil width, a is a constant number in the following function: λ=1+ar/weq; where λ is the ratio of the peak field to the central field. The above expression is valid for the short sample field: a critical aspect is the margin on the load line (one minus the ratio between operating current and short sample current), which usually ranges between 20% and 30% in most accelerator magnets. Due to the position of the magnet, which is right after the interaction point and therefore heavily irradiated, we take a conservative margin of 30%, i.e. it works at Bop=0.7 Bss. The iron effect can be calculated roughly by using the following equation, with the assumption that the iron is not saturated, the permeability is uniform, and the thickness of iron is infinite [5] B1iron 1 ( r w) r noniron 1 R I2 B1 (2) where RI is the inner radius of iron yoke. If we assume the spacer thickness between coil and iron yoke is around 20 mm, a filling factor of k=0.34, a=0.05, we get the dependence of central magnetic field Bop on coil width for Nb-Ti superconductor, as shown in Fig. 2. For Nb3Sn superconductor, we have a similar equation with (1) [4] Bss kc 0 weq 4b 1 1 2 kc 0 ( weq ar ) III. DESIGN WITH NB-TI LHC DIPOLE CABLE (INNER) A. Main electromagnetic parameters We studied the two cases (150 mm aperture and 130 mm aperture) for the Nb-Ti LHC dipole cable (inner) by using ROXIE [6]. The coil layout is optimized at the nominal operating current. The target is to reduce the multipole coefficients from b3 to b13 to less than 1 unit (10-4 relative to the main field) at 2/3 of the aperture radius. The proposed cross-section of the magnet for the 150 mm (diameter) case is shown in Fig. 3. Six coil blocks are distributed in two layers in each quadrant of cross-section, and the same superconducting cable is adopted for the inner and outer layers (no grading, since it would increase stresses). The outer diameter of the iron yoke is 550 mm, which is identical to the size of the current LHC dipole magnets. A ~20 mm spacer is placed between the iron yoke and coil packs. The diameter of the heat exchanger of the current design is 50 mm. If necessary, it can be increased to above 80 mm. Assuming the load line margin is 30% at 1.9 K, the nominal dipole field of the magnet is ~ 6.4 T and the operating current is ~ 9.3 kA. The average stress in coil caused by Lorenz force is 50-70 MPa. The parameters of the magnet, cable and strand are listed in Table II; the coil layout parameters are listed in Table III; Fig. 4 and 5 show the magnetic field distribution in the coil and iron yoke with the aperture diameter of 150 mm. (3) the corresponding result is also included in Fig. 2. The second choice we make is the coil thickness. We choose a rather large coil thickness to decrease the current density and therefore the stresses, which are large in the case of large aperture dipoles. For this reason we propose 30 mm arranged in two layers of 15 mm each, as in the LHC main dipoles. An aperture variation from 120 to 180 mm gives little impact on the operational field. In Fig. 2 the 4.2 K case is also shown. 9 Central magnetic field B (T) With iron and load line ratio 70% 8 7 Fig. 3: The cross-section of the magnet with aperture diameter of 150 mm. 6 5 4 NbTi r=65mm @ 4.2K NbTi r=75mm @ 4.2K ITER Nb3Sn r=65mm @ 4.2K ITER Nb3Sn r=65mm @ 1.9K 3 10 20 30 NbTi r=65mm @ 1.9K NbTi r=75mm @ 1.9K ITER Nb3Sn r=75mm @ 4.2K ITER Nb3Sn r=75mm @ 1.9K 40 50 60 Equivalent width of the coil defined in [1] (mm) Fig. 2: The dependence of Bss on weq for aperture diameter of 130 mm and 150 mm, with load line margin 30%. Fig. 4: The magnetic field distribution in the coil for 150 mm aperture. 3 B. Effect of iron saturation and filament magnetization on field quality The type of iron used for this magnet is the same as that of the MQXA magnet [7]. The peak field in the iron yoke is ~3.8 T at the nominal operating current, as shown in Fig. 5; most parts of the iron are saturated. Iron saturation causes the variation of sextuple and decapole coefficients along with the increasing of the operating current. Another source of severe field distortions at low excitation is persistent magnetization currents. It is proportional to the filament diameter and the critical current density of the superconductor [8]. The persistent magnetization currents generate all multipoles which are allowed by coil symmetry, and the multipole fields have opposite signs for increasing and decreasing main field. Fig. 5: The magnetic field distribution in the iron yoke for 150 mm aperture. TABLE II: KEY PARAMETERS OF THE MAGNET WITH LHC DIPOLE CABLE (INNER) Value 150 mm 130 mm 6.35 T 6.48 T 9.3 kA 9.2 kA <0.01% (Rref=50/43 mm) 7.06 T 7.08 T 70% / 63.7% 70% / 64.8% @1.9 K @1.9 K 2.9 K 2.9 K 16.1 / 13.6 12.8 / 10.6 mH/m mH/m 588.1 kJ/m 448.6 kJ/m 2/6 1.11 1.09 2.1/0.97 MN/m 1.96/0.86 MN/m 71 MPa 57 MPa 550 mm 254 mm 234 mm 1.065 1.65 15.1* 1.9mm2 / 0.16 mm (radial) 0.135 (azimuthal) 28 1.24 ° 1000 A/mm2 989 A/mm2 Ratio 1.15 0.98 1.01 / 0.997 1 COIL BLOCKS RADIUS (MM) 150 1 2 3 4 5 6 1 2 3 4 5 6 75 75 75 75 91 91 65 65 65 65 81 81 PHI (DEG) 1.0032 25.9868 49.0401 68.0 0.6440 30.0936 130 1.0678 27.3967 50.5653 69.0 0.9015 26.9318 * Phi – positioning angle; Alpha – Inclination angle. 150 mm aperture 130 mm aperture 25 1.31 / 1.02 / 1.25 / 1.09 / / / / / 1.01 TABLE III: COIL LAYOUT PARAMETERS FOR 2 CASES APERTURE DIAMETER (MM) 30 1 1.28 Multipole coefficients b3 Item Bore diameter Nominal field (dipole) Operating current Field homogeneity Peak field in the coil Load line ratio (Inner / Outer layer) Temperature margin Inductance (low field / nominal field ) Stored energy No. of layers/blocks Peak field/central field Lorenz force X/Y Estimated coil stress Outer dia. of iron yoke Inner dia. of iron yoke Strand diameter Cu/Non-Cu ratio Cable dimension / Insulation No. of strands Keystone angle Supercon. current density Fig. 6 shows the dependence of sextuple coefficient on the operating current for the current design caused by the effect of iron saturation and filament magnetization. The filament diameter of the Nb-Ti strand is ~ 7 μm. In both cases, the variation of b3 from injection (~500 A) to the nominal current is about 30 units. The influence on the other multiple coefficients (b5, b7 …) is less than 1 unit. Table IV shows the field quality at different operating currents in the ramp-up and ramp-down processes. Simulations are needed to check if these large multipoles are tolerable at injection or if a corrective strategy should be envisaged. Fig. 7 shows the transfer function of the magnet caused by iron saturation. It decreases by ~ 13% from low current to the nominal current. 20 15 10 5 0 -5 0.5 1.5 2.5 3.5 4.5 5.5 6.5 7.5 8.5 9.5 Operating current (kA) Fig. 6: The effect of iron saturation and filament magnetization on b3. The influence of iron cryostat is not included. ALPHA NO. OF (DEG) CONDUCTORS 0 23.0157 54.0 75.0 0 28.5926 0 23.0 45.0480 75.0 0 26.2173 15 10 7 5 17 20 13 8 6 4 15 21 TABLE IV: FIELD QUALITY IN THE RAMP-UP AND RAMP-DOWN PROCESSES (INFLUENCE OF IRON CRYOSTAT IS NOT INCLUDED) APERTURE DIAMETER (MM) OPERATING CURRENT (KA) B3 B5 B7 B9 B11 B13 150 0.5 4.5 9.3 4.5 0.5 0.5 4.5 9.2 4.5 0.5 10.9 14.0 0.2 14.6 28.5 -4.9 4.8 0.1 5.4 12.8 0.3 -0.2 -0.4 -0.2 -0.1 -0.2 -0.5 -0.4 -0.5 -0.7 0.4 0.8 0.5 0.8 1.1 0.4 0.7 0.5 0.7 1.0 -0.4 -0.5 -0.6 -0.5 -0.5 -0.5 -0.5 -0.6 -0.5 -0.5 0.3 0.3 0.4 0.4 0.4 0.4 0.5 0.5 0.5 0.5 0.1 0.0 0.0 0.0 0.0 0.1 0.0 0.1 0.0 0.0 130 4 0.82 150 mm aperture Transfer function (T/kA) 0.8 130 mm aperture 0.78 0.76 0.74 0.72 0.7 0.68 0.66 0.5 1.5 2.5 3.5 4.5 5.5 6.5 7.5 8.5 9.5 Operating current (kA) C. Stray field and field quality in the aperture including the influence of iron cryostat Although the new D1 magnet has a large aperture, the current design assumes a limited diameter of the iron yoke to be 550 mm. The stray field of the magnet is relatively high. Assuming the size of the cryostat is the same with the current LHC cryostat: the outer diameter is 914 mm and the thickness is 12 mm; the magnet is 80 mm offset from the center of the cryostat, the maximum stray field at the outer surface of the iron cryostat is ~ 0.14 T for aperture diameter of 150 mm and ~ 0.1 T for aperture diameter of 130 mm, as shown in Fig. 8 and Fig. 9. A simple method to reduce the stray field is to increase the thickness of the iron yoke. Fig. 10 shows the variation of the stray field with different sizes of iron yoke. If we need to reduce the stray field to less than 0.05 T at the outer surface of the cryostat, the required diameter of the iron yoke is over 0.7 m for an aperture diameter of 150 mm. Fig. 9: Stray field at the outer surface of the iron cryostat for 150 mm aperture and at nominal current (from 0 to 360 degrees, anti-clock direction). 0.18 0.16 Stray field (T) Fig. 7: Transfer function of the magnet caused by iron saturation. 0.14 0.12 0.1 0.08 0.06 0.04 0.5 0.55 0.6 0.65 0.7 Yoke outer diameter (m) Fig. 10: Maximum stray field at the outer surface of the cryostat with different sizes of iron yoke for 150 mm aperture magnet. Fig. 11 and Table V show the influence of iron cryostat on the field quality in the aperture. The iron cryostat is not included in the model during the optimization of the current coil layout. Without iron cryostat, all the normal multipole coefficients are less than one unit within the reference radius (2/3 of the aperture radius); if we include the iron cryostat, but the magnet is located at the center of the cryostat, b3 will be increased from less than 1 unit to larger than 5 units; if we further move the magnet from the center of the cryostat to the upper side by 80 mm, the skew multipoles will be generated, i.e. a2 is ~ 2.5 units in this situation. TABLE V: FIELD QUALITY IN THE 150 MM APERTURE INCLUDING IRON CRYOSTAT AND AT THE NOMINAL CURRENT Fig. 8: Magnetic field in the iron yoke and iron cryostat for 150 mm aperture and at nominal current. CONDITIONS B3 B5 IN FIG. 11 (A) 0.2 -0.4 (B) 5.8 -0.3 (C) 5.9 -0.3 * Reference radius:& 50 mm. All below 0.1 unit. B7 B9 B11 B13 A2 A4 0.5 -0.6 0.4 0.0 0 0 0.5 -0.5 0.4 0.0 0 0 0.5 -0.5 0.4 0.0 -2.5 -0.3 the other normal and skew multipoles are 5 Fig. 12: The cross-section of the magnet with aperture diameter of 150 mm. Fig. 11: Field quality in the 150 mm aperture: (a) magnet without iron cryostat; (b) magnet centered in the iron cryostat, b3 > 5 units; (c) magnet 80 mm offset from the center of the iron cryostat, b3 > 6 units,a2 > 2 units. IV. DESIGN WITH BRONZE NB3SN CABLE A. Main electromagnetic parameters The higher Critical temperature of bronze route Nb 3Sn is expected to provide more enthalpy margin than Nb-Ti to against the heat deposition by irradiation. We studied the two cases (150 mm aperture and 130 mm aperture) by using 11 mm wide bronze Nb3Sn cable. The coil layout is optimized at the nominal operating current. The target is to reduce the multipole coefficients from b3 to b13 to less than 1 unit at 2/3 of the aperture radius. The proposed cross-section of the magnet for the 150 mm (diameter) case is shown in Fig. 12. Six coil blocks are distributed in two layers in each quadrant of cross-section, and the same superconducting cable is adopted for the inner and outer layers. The outer diameter of the iron yoke is 550 mm. A ~ 20 mm spacer is placed between the iron yoke and coil packs. The diameter of the heat exchanger is 50 mm. If necessary, it can be increased to above 80 mm. Assuming the load line margin is 30% at 1.9 K, the nominal dipole field of the magnet is ~ 6.2 T, and the operating current is ~ 7 kA. The average stress in coil caused by Lorenz force is around 100 MPa. The parameters of the magnet, cable and strand are listed in Table VI; the coil layout parameters are listed in Table VII; Fig. 13 and 14 show the magnetic field in the coil and iron yoke with aperture diameter of 150 mm. Fig. 13: The magnetic field in the coil with aperture diameter of 150 mm. Fig. 14: The magnetic field in the iron yoke with aperture diameter of 150 mm. 6 130 1 2 3 4 5 6 65 0.8645 65 28.3592 65 51.9829 65 69.0 77 0.5 77 33.4382 * Phi – positioning angle; Alpha – Inclination angle. 0 32.6823 45.4294 75.0 0 29.5739 35 18 11 8 5 20 17 150 mm aperture 130 mm aperture 25 Multipole coefficients b3 B. Effect of iron saturation and filament magnetization on field quality The type of iron used for this magnet is the same as that of the MQXA magnet [7]. The peak field in the iron yoke is ~3.6 T at the nominal operating current, as shown in Fig. 14; most parts of the iron are saturated. Fig. 15 shows the dependence of sextuple coefficient on the operating current caused by the effect of iron saturation and filament magnetization. The filament diameter of the Nb3Sn strand is ~ 10 μm. In both cases, the variation of b3 from injection (~350 A) to the nominal current is about 40 units. The influence on the other multiple coefficients (b5, b7 …) is less than 1 unit. Table VIII shows the field quality at different operating currents in the ramp-up and ramp-down processes. Simulations are needed to check if these large multipoles are tolerable at injection or if a corrective strategy should be envisaged. Fig. 16 shows the transfer function of the magnet caused by iron saturation. It decreases by ~ 13% from low current to the nominal current. 15 5 -5 -15 TABLE VI: KEY PARAMETERS OF THE MAGNET WITH LHC DIPOLE CABLE (INNER) Item Bore diameter Value 150 mm (MBXE) 130 mm (MBXD) Ratio 1.15 Nominal field (dipole) 6.19 T 6.31 T 0.98 Operating current 7.1 kA 7.0 kA 1.01 Field homogeneity <0.01% (Rref=50/43 mm) -25 0 1 2 3 4 5 6 7 Operating current (kA) Fig. 15: The effect of iron saturation and filament magnetization on b3. The influence of iron cryostat is not included. / TABLE VIII: FIELD QUALITY IN THE RAMP-UP AND RAMP-DOWN PROCESSES (INFLUENCE OF IRON CRYOSTAT IS NOT INCLUDED) Peak field in the coil 7.02 T 7.04 T 0.997 Load line ratio (Inner / Outer layer) Temperature margin 70.4% / 64.5% @1.9 K / 70.1% / 64.8% @1.9 K / 1 APERTURE DIAMETER (MM) OPERATING CURRENT (KA) B3 B5 B7 B9 B11 B13 / Inductance (low field / nominal field ) Stored energy 23.1 / 20.1 mH/m 507 kJ/m 18.0 / 16.3 mH/m 399 kJ/m 1.23 150 0.35 3.5 7 3.5 0.35 0.35 3.5 7 3.5 0.35 -0.2 16.2 0.9 17.3 33.3 -24.4 -4.8 0.1 -3.7 10.1 0.7 0.0 -1.0 0.0 0.0 0.1 -0.3 -0.9 -0.3 -0.5 0.5 1.1 0.9 1.2 1.8 0.3 1.0 0.8 1.1 1.8 -0.5 -0.6 -0.7 -0.6 -0.7 -0.7 -0.9 -1.0 -0.9 -1.0 0.7 0.7 0.8 0.7 0.8 0.7 0.8 0.9 0.8 0.8 -0.5 -0.5 -0.6 -0.5 -0.5 -0.9 -0.8 -0.9 -0.8 -0.8 No. of layers/blocks 1.27 2 layers; 6 blocks / Peak field/central field 1.13 1.12 1.01 Lorenz force X/Y 1.92/0.87 MN/m 1.78/0.77 MN/m / Estimated coil stress 103 MPa 86 MPa 1.2 220 mm 1.09 Outer dia. of iron yoke Inner dia. of iron yoke 550 mm 240 mm 130 / Strand diameter 0.82 / 1.02 Cu/Non-Cu ratio 0.97 / 1 Cable dimension / insulation No. of strands 11.0* 1.48mm2 / 0.15 mm (radial) 0.15 mm (azimuthal) 26 / 1.2 ° / Supercon. current density 1033 A/mm 2 1018 A/mm 0.98 / 2 1.01 TABLE VII: COIL LAYOUT PARAMETERS FOR 2 CASES APERTURE COIL RADIUS DIAMETER (MM) BLOCKS (MM) 150 1 2 3 4 5 6 75 75 75 75 91 91 PHI (DEG) 0.5841 26.3382 49.9177 68.7 1.2 32.4817 ALPHA NO. OF (DEG) CONDUCTORS 0 31.681 53.9957 74.9993 0 33.4981 19 13 10 6 22 18 Transfer function (T/kA) Keystone angle 150 mm aperture 130 mm aperture 0.96 0.94 0.92 0.9 0.88 0.86 0 1 2 3 4 5 6 Operating current (kA) Fig. 16: Transfer function of the magnet caused by iron saturation. 7 7 V. SUMMARY The conceptual design work of the new D1 magnet for HL-LHC upgrade is ongoing. The aperture diameter of this magnet is 130-150 mm. Assuming a 30 mm wide coil by using Nb-Ti LHC dipole cable (inner), or a 22 mm wide coil by using bronze Nb3Sn cable; and a 30% margin on the load line, the central magnetic field is 6.2 – 6.5 T at 1.9 K. The magnet length is ~ 7 m to reach the integrated field of 40 T m. Nb3Sn design with low-Jc ITER strand provides similar field as in Nb-Ti, but 2-3 times larger temperature margin. The average stress in coil caused by Lorenz force is 50-70 MPa for Nb-Ti option, around 100 MPa for Nb3Sn option. The stray field is around 0.14 T for 150 mm aperture and 0.1 T for 130 mm aperture at the outer surface of the iron cryostat. If we need to reduce the stray field to less than 0.05 T, the required diameter of the iron yoke is over 0.7 m for 150 mm aperture. Good field quality will be only required at the beam collision. Further study on the strong saturation effects of the iron yoke will be carried out and accordingly the shape of the iron yoke will be modified. The 3D coil end design, mechanical design, thermal analysis will be done afterwards. ACKNOWLEDGEMENT This work is carried out both at the Cryogenics Science Center of KEK and TE-MSC group of CERN. The authors would like to thank all the colleagues in these two groups, for their kind support of this R&D work. Special thanks go to Thomas Taylor (CERN) for his helpful comments on this work and Bernhard Auchmann (CERN) for his kind technical support on the ROXIE software. 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