Optimizing the use of pressurized bladders for the assembly of HL-LHC MQXFB magnets

TL;DR

This paper presents an optimized bladder and keys assembly process for Nb3Sn accelerator magnets, reducing overstress during assembly and improving the reliability of long magnet construction for the LHC upgrade.

Contribution

It introduces a new bladder assembly method that eliminates overstress in Nb3Sn magnets, validated through experiments and finite element modeling.

Findings

Elimination of coil overstress during assembly.

Validation of the method in full-length models.

Implementation as the new CERN baseline for series production.

Abstract

The use of pressurized bladders for stress control of superconducting magnets was firstly proposed at Lawrence Berkeley National Laboratory (LBNL) in the early 2000s. Since then, the so-called bladders and keys procedure has become one of the reference techniques for the assembly of high-field accelerator magnets and demonstrators. Exploiting the advantages of this method is today of critical importance for Nb3Sn-based accelerator magnets, whose production requires the preservation of tight stress targets in the superconducting coils to limit the effects of the strain sensitivity and brittleness of the conductor. The present manuscript reports on the results of an experimental campaign focused on the optimization of the bladders and keys assembly process in the MQXFB quadrupoles. These 7.2 m long magnets shall be among the first Nb3Sn cryomagnets to be installed in a particle accelerator as a part of the High Luminosity upgrade of the LHC. One of the main practical implications of the bladders technique, especially important when applied to long magnets like MQXFB, is that to insert the loading keys, the opening of a certain clearance in the support structure is required. The procedure used so far for MQXF magnets involved an overstress in the coils during bladder inflation. The work presented here shows that such an overshoot can be eliminated thanks to additional bladders properly positioned in the structure. This optimized method was validated in a short model magnet and in a full-length mechanical model, becoming the new baseline for the series production at CERN. Furthermore, the results are supported by numerical predictions using Finite Element models.