Progress and Scope of 325 and 650 MHz RF Couplers

The document outlines the technical progress and scope of work regarding the development of 325 MHz and 650 MHz RF couplers for the Joint Review Meeting. It includes details on milestones, design and fabrication timelines, prototype testing results, production updates, and plans for increasing power limits. The focus is on the ongoing efforts by Rajesh Kumar, Sergey Kazakov, and collaborating teams to enhance the efficiency and performance of the couplers.

• RF Couplers
• Technical Progress
• Prototype Testing
• Fabrication
• Power Coupler

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1. 325 and 650 MHz RF Couplers (Section 6.3,6.4,6.5) Rajesh Kumar, DAE-SPC Sergey Kazakov, Fermilab-SPM IIFC Joint Review Meeting 11-12 July 2016 BARC, Mumbai

2. Outline Scope of work Status Technical Schedule Issues requiring management attention Technical Schedule Summary Kazakov & Kumar | 325 MHz & 650 MHz RF Coupler 7/6/16 2

3. Scope of work Power Couplers (Section 6.6 of Joint Project Document, page 12) S. No. Major Milestone Quantity Delivery date 1 (a) Design of 325 MHz Power Coupler Done (b) Design of 650 MHz Power Coupler 31 May 2016 2 (a) Fabrication of 325 MHz Power Coupler 3 31 Dec 2016 (b) Fabrication 650 MHz Power Coupler 6 30 July 2017 Milestones 1 (designs) are deliverables of FNAL and Milestones 2 (fabrication) are deliverables of DAE. 3

4. 325 MHz RF Couplers S. No. Major Milestone Qty Delivery date Proposed revised delivery date 1a Design of 325 MHz Power Coupler Done * [To be given by FNAL] * (*) FNAL had supplied the prototype design drawings (pdf and sat files) and coupler specifications to DAE in Dec 2015. However, the final (325 MHz) SSR1 production coupler design will be released pending successful high-power bench testing, and the (325 MHz) SSR2 coupler design is still evolving. 2a Fabrication of 325 MHz Power Coupler 3 31 Dec 2016 16 months from completion of Milestone 1a 4

5. Technical Progress: 325 MHz couplers (Fermilab) Three prototype couplers were fabricated. Two couplers were successfully tested up to 30 kW, CW, full reflection Couplers were tested to failure. One coupler was destroyed at power level ~ 47 kW, CW, full reflection Third coupler is used routinely in STC with SSR-I cavity at power level ~ 10 kW, CW, full reflection. 10 couplers are under production at Mega Industries, LLC Two couplers were delivered recently Couplers have passed QC. Quality looks better then quality of prototypes. Based on test results of prototypes we decided to modernize slightly the 325 MHz couplers for SSR2 to increase a power limit. Kazakov & Kumar | 325 MHz & 650 MHz RF Coupler 7/6/16 5

6. 325 MHz Production Couplers, Mega, LLC Kazakov & Kumar | 325 MHz & 650 MHz RF Coupler 7/6/16 6

7. 325 MHz Coupler, high power test stand Kazakov & Kumar | 325 MHz & 650 MHz RF Coupler 7/6/16 7

8. 650 MHz RF Couplers Milestone Major Milestone Qty Delivery date Remarks 1b Design of 650 MHz Power Coupler 31 May 2016 To be given by FNAL (*) (*) FNAL is still finalizing a new design of the 650 MHz couplers. 2b Fabrication of 650 MHz Power Couples 6 30 July 2017 16 months from completion of Milestone 1b 8

9. Technical Progress: 650 MHz coupler (Fermilab) Based on tests results of 325 MHz couplers and on new ideas, the 650 MHz coupler will be modernized: Diameter of ceramic window will be increased from 3 to 4 (to increase power limit). Diameter of inner conductor of ceramic window will be increased from 0.5 to 1 . It will decrease a current density at brazing place and makes window less sensitive to brazing defects (more reliable). Matching element will be placed to antenna. It will serve as shield of ceramic against charged particles. Two versions of coupler are under design: One uses EM shields instead of copper coating. Other one utilize a traditional copper coating. Kazakov & Kumar | 325 MHz & 650 MHz RF Coupler 7/6/16 9

10. 650 MHz coupler, version 2 cold end design Plan: Complete RF, thermal, and mechanical designs. Prototype both cold end designs. Approve and release complete coupler drawing sets Fabricate Prototypes. Kazakov & Kumar | 325 MHz & 650 MHz RF Coupler 7/6/16 10

11. Technical Issues: DAE notes and Fermilab Response DAE Notes (325 MHz Power Coupler) FNAL had supplied the prototype design drawings (pdf and sat files) and coupler specifications to DAE in Dec 2015. However, the final design drawings including specifications (FRS, TRS) and design documents are being finalized by FNAL. 16 months from completion of Milestone 1a Fermilab Response: Fermilab SSR1 RF Coupler information resides in Teamcenter. ED0001258 Fermilab has been doing extensive testing and several design improvements have been introduced for SSR2 and HB/LB650 couplers. Final Build to Print drawings for 325MHz RF couplers will be released to DAE after we certify the latest batch from US industry. The Joint R&D Document has DAE fabricating these couplers as a technology transfer to DAE. The DAE coupler production schedule is not critical for the Fermilab R&D program. Kazakov & Kumar | 325 MHz & 650 MHz RF Coupler 7/6/16 11

12. Technical Issues: DAE notes and Fermilab Response DAE Notes (650 MHz Power Coupler) One 650 MHz coupler is required urgently for integration with the first HTS-2 at RRCAT (that will be delivered to FNAL). Since there is a delay in the design of the 650 MHz RF coupler, it is likely to affect the HTS-2 schedule. This issue needs to be addressed. Fermilab Response: Fermilab 650 MHz RF Coupler information resides in Teamcenter. ED0001260 Fermilab is on schedule to release the Build to Print prototype drawings by 31st Oct 2016. Kazakov & Kumar | 325 MHz & 650 MHz RF Coupler 7/6/16 12

13. Summary SSR1 production RF coupler bench testing under way at Fermilab. Final SSR1 production coupler design will be released pending successful high-power bench testing. Design modifications needed to meet SSR2 specifications will be based on high power bench testing. 650 MHz RF coupler prototype design is scheduled to be released 31 Oct 2016. Fabrication of the 325 and 650 MHz couplers at DAE will be completed 16 months after approval dates. The delay in the 650 MHz coupler design will affect the HTS-2 schedule; this issue needs to be addressed urgently. Kazakov & Kumar | 325 MHz & 650 MHz RF Coupler 7/6/16 13

14. 325 MHz coupler, structure 325 MHz SSR1 Production Design Kazakov & Kumar | 325 MHz & 650 MHz RF Coupler 7/6/16 14

15. 325 MHz Coupler, low power test bench Kazakov & Kumar | 325 MHz & 650 MHz RF Coupler 7/6/16 15

16. 650 MHz Coupler, structure, version 1 cold end design Kazakov & Kumar | 325 MHz & 650 MHz RF Coupler 7/6/16 16