LCLS Week 2 The Extruded Aluminum vacuum chamber

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LCLS Week 2The Extruded Aluminum vacuum chamber

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Progress to Date

• Polishing continues
• Twenty-five pieces already delivered to Hi-Tech
  for Machining
• We continued to adjust the recipe for polishing
  as we went along up to this pointwe now feel we
  can polish more consistently within a more
  satisfying range.
• Ten more pieces scheduled for delivery to Hi-Tech
  on 1/30
• The remaining ten pieces to be delivered to
  Hi-Tech in early February

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Polishing Results So Far
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Progress continued

• Machining continues
• Six production chambers delivered to ANL
• Chamber machining was temporarily on hold for
  machining of chamber alignment plates
• This hold period allowed us to learn a little
  more about the alignment and machining of the
  production chambers
• All 120 plates now fully machined.
• The next batch of production chambers now being
  machineddelivery anticipated 2/3.

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Vacuum Chamber Specifications

• A draft Engineering Specification Document (ESD)
  is written. Requirements are below.

Parameter Value Achieved
Thickness of chamber at aperture 6.00 .15/-.05 mm 5.995 6.122 mm
Aperture height 5.00 .08 mm 4.990 5.118 mm
Overall flange to flange length 3464.44 0.2/-0.8 mm 3463.90 min 3464.64 max
Vertical straightness of the mounted chamber after alignment 0.050 mm 0.059 mm worst case
Beam stay-clear radius around the chamber aperture axis 2.3 mm 2.47 mm worst case
Average rms slope error goal of aperture in both longitudinal and transverse directions best effort See table -
Average vacuum pressure lt 10-6 Torr lt5 x 10-7
RGA mass scan All peaks 44 AMU All peaks 44 AMU
Vacuum chamber material 6063 aluminum 6063 aluminum
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LCLS VC thickness inspection
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LCLS VC dimensional inspection and installation
test
LCLS VC on the alignment stand
LCLS VC on the granite table for the length
inspection
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Inspection and correction of the LCLS VC end
flange perpendicularity (.003 - .004 precision)
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Inspection of the end length of the LCLS
VC(.001 precision)
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Two LCLS VC on the baking stands
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Progress continued

• First Delivery to LCLS Soon
• On 1/28, the first five chambers will depart ANL

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First production LCLS VC in the shipping crate
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The Schedule
Event Original Completion Date Updated Completion Date
Polishing of extrusions 12/07/07
Straightening of extrusion
Machining of extrusions 4/21/08
Chamber Processing at ANL 4/23/08
Ship Chambers 1-5 to SLAC 1/23/08 2/1/08
Ship Chambers 6-10 to SLAC 1/28/08 2/22/08
Ship Chambers 11-20 to SLAC 3/10/08 3/14/08
Ship Chambers 21-30 to SLAC 3/26/08 4/4/08
Ship Chambers 31-40 to SLAC 4/25/08 4/29/08
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What we learned along the way

• The overall length is difficult to predict
  precisely due to shrinkage during the welding of
  the ends.
• The Dycor RGA heads short out easily.
• Two shorts in five chambers???
• The alignment system
• We are evaluating other options that we hope may
  be easier to use.
• Eliminate the compound screw that limits roll
  adjustment???

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Minor changes in LCLS VC design to simplify its
alignment
First six chambers
All other chambers
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CONCLUSION

• Manufacturing and certification of the LCLS
  vacuum chambers is proceeding according to our
  schedule and within the allocated budget

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ACKNOWLEDGMENTS

• A special thank you to
• Mark Erdmann,
• Joe Gagliano, George Goeppner,
• Dana Capatina, Scott Doran, Esiquio Salazar,
  Kevin Knoerzer, Russel Otto, Dan Nocher, Mike
  Bosek, Dan VanLannan,
• Wayne Michalek, Mark Martens, Paul Aguirre,
  Aaron Lopez,
• Lahsen Assoufid, Jun Qian, Albert Macrander
• Frank Bock (Cardinal aluminum Co.),
• Don Fulcher, Tom Inwood (Engineered
  Finishing Co.),
• Simon Sorsher (Hi-Tech Mfg.).