LCLS Cavity BPM Production Status

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LCLS Cavity BPM Production Status
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M1-Tool Works BPM Production

• M1 awarded contract for machining bodies and
  transitions for 20 sets of parts
• First Production BPM mechanical measured and
  Pre-lim cold test look very good

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First production unit
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Cavity Production Status

• M1-Tool Works to deliver 11 units 1/22/08
  presently on schedule
• Exercised the option for additional 20 units
  order from M1-Tool 1/08
• Parts are on time and in spec so far

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Cold Test Set-Up for Pre-Braze test

• New production test fixtures for pre-braze
  testing
• First production unit looks good and parts are at
  Altair waiting to be brazed

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Cavity BPM Cold Test Data
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First Production Unit Shipped to

• Serial 010 shipped to Altair for brazing
  12/21/07
• Unit pending complete braze due to window problem

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Production Risks (Presented at FAC 10/30/07)

• New End Cap design
• New tuning scheme
• Window plating problem
• Unexpected integration problem
• Unexpected vendor problem

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The Window Braze Yield Problem

• Problem brazing the window into the transition
  has caused delivery delay
• Convergence and down-select of possible solutions
  pending
• Concentration of effort critical

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Understanding the Problem

• History
• Why were ALL the soldered units vacuum tight?
• 15 for 15
• Why did the units built for the 3-BPM work so
  well compared to present results
• 6 small leaks, 9 good NO CRACKING

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BPM Window Braze History

• Prototype cold test unit, ITS test unit and 3-BPM
  test unit S/N 01 soldered Sn-Ag-Cu Vacuum tight
• 2 test brazes Georo Vacuum tight
• 3-BPM S/N R/0 first Georo braze Vacuum tight

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Georo Test Braze before 3-BPM units

• First test brazes clean and vacuum tight 5/12/07
• No risk at this time so units for 3-BPM testing
  would be processed with Georo braze material

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First Problem Window

• 3-BPM test Ser 03 Georo Braze Results
• 2 out of 5 leaked and the 2 that leaked had
  glossy Ni plating
• 3-BPM test Ser 02 Georo Braze Results
• 4 out of 5 leaked and the 4 that leaked had
  glossy Ni plating

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Corrective Action from 3-BPM Window Failures

• Start RD program to identify problem with bright
  Ni
• CPI suggested using gold plating of first trials
• First sample failed 10/07 because of apparent
  cracks and spattering
• Possible cause was cool down too rapid

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Window Problem Status 01/21/08

• Moly retaining ring and retaining outer block
• Lower temperature braze (Orotin) with induction
  heating re-work
• CPI supplies transition with window installed
• Kovar frame
• Two piece transition
• Bolt on window
• Coax adapter

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Cavity BPM Production Recovery Options without
changing the design

• Option 1 Lower temperature braze (Orotin) and
  Induction heating re-work plan
• Option 2 Work with CPI for a turn-key solution
  providing completed transition
• Option 3 Braze window into a frame (Kovar) with
  similar expansion coef and weld into transition

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Braze with existing/modified parts

• PROs
• Lowest risk option
• Fastest recovery
• Re-work plan possible
• Lowest cost impact
• No risk to qualified BPM system design

• CONs
• Yield not satisfactory
• Re-work plan needs work

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Induction Heating

• Working with Ameritherm to re-work window after
  failed braze
• Braze can be re-worked by applying additional
  paste or powder to joint

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Receiver Electronics Production Status

• All parts on order
• Test fixtures developed
• Parts to start arriving 2/08

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Production Status

• M1-tool Works delivered first unit 11/07 on time
  and in spec
• First unit has been QA tested and cold tested
  with very good results
• First unit is at Altair being Brazed less
  waveguide transitions
• ANL to supply Altair with first set of modified
  window/transitions
• Addition 11 BPMs in process at ANL

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Production Milestones

• Production of 1 BPMs for LTU 02/08
• Production of 11 BPMs for undulator/LTU 03/08
• Production of 12 BPMs for undulator 04/08
• Production of 12 BPMs for undulator 05/08
• Spares 4 BPMs 06/08
• 40 sets of Electronics 08/08