Development of a 120-mm Aperture Nb3Sn Dipole Coil with Stress Management

TL;DR

This paper presents the design, fabrication, and testing of a 120-mm aperture Nb3Sn dipole coil with integrated stress management, utilizing additive manufacturing for support structures to improve coil performance.

Contribution

It introduces a novel stress management structure for Nb3Sn dipole coils and demonstrates its fabrication and testing using additive manufacturing techniques.

Findings

Successful fabrication of the stress management support structure

Effective coil stress control demonstrated in tests

Feasibility of using 3D printing for coil support structures

Abstract

This paper describes a 120-mm aperture 2-layer dipole coil with stress management (SM) developed at Fermilab based on cos-theta coil geometry. A model of the coil support structure made of plastic was printed using additive manufacturing technology and used for practice coil winding. The real coil support structure was printed using the 316 stainless steel. The results of the SM structure size control and the key coil fabrication steps are reported in the paper. The design of coil SM structure and the coil FEA in the dipole mirror test configurations are presented and discussed.