Manufacturing and Quality Assurance

Magnet Production Workshop

Frank DePaola
April 11-12, 2012

BROOKHAVEN SCIENCE ASSOCIATES

Abstract
Manufacturing and Quality Assurance
Frank DePaola, NSLS-II Project
Building Quality into the Magnets necessitates that the quality requirements for the performance specifications
are incorporated into the production process and methods used to produce the magnets. This is accomplished
through manufacturing travelers, documented procedures, early QA involvement that takes a proactive approach
for preventing defects, and the use of established best practices for manufacturing the coils and yokes.

*Work performed under auspices of the United States Department of Energy, under contract DE-AC0298CH10886

DOE Review of the NSLS II Project, November 15 - 17, 2010

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OUTLINE

Manufacturing and Quality Assurance Interface

Magnet Production

Build Quality into the Product

Manufacturing Travelers
Role of Quality Assurance in Manufacturing
Magnet Yoke Fabrication
Magnet Coil Fabrication
Magnet Assembly
Magnet Production Workshop April 11-12, 2012
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Build Quality Into The Product

Successful manufacturers build quality into their products

The quality necessary to achieve the required specification is designed

and planned into the product upfront it than becomes integrated into
the manufacturing methods used to produce the product

This is accomplished through the use of manufacturing travelers,

documented procedures, inspection and test plans, engineered tooling
and fixtures, and continuous improvement

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Manufacturing Travelers
The single most important item is the manufacturing traveler

Sequential listing of required tasks

References special work instructions and procedures
Incorporates in-process inspection and test requirements
Captures individual part data (actual measurements & test results)
Provides hold points that require approval prior to proceeding
Historical record for each individual item produced
Provides consistency from part to part throughout the production run

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Role of Quality Assurance in Manufacturing

Provide a systematic and proactive approach for preventing defects

Implement procedures that ensure manufactured products consistently

meet the required quality specifications

Incorporate the QA requirements into the manufacturing traveler

Perform audits to ensure:

Established procedures are being followed

Personnel performing the work are adequately trained
Equipment is calibrated and in good repair
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Magnet Yoke Fabrication

MATERIAL

Ideally all magnets from the same family are manufactured from a
single batch of steel (same heat)

Shuffling systematically distributes the steel properties among all the

yoke segments and ensures that all the magnets in a single family
have reproducible and uniform magnetic properties

Sorting ensures that variations in the sheet thickness (caused by

crowning during the rolling process) are systematically distributed If
the laminations are symmetrical they can be flipped during the stacking
process
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Magnet Yoke Fabrication

Solid Steel Yokes or Steel Laminated Yokes
Solid Steel Yokes
Machined from a solid block of material
Cannot be cycled or pulsed rapidly (eddy currents)
Acceptable for use in storage ring accelerator applications
Should be considered if a small number of magnets are
required

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Magnet Yoke Fabrication

Solid Steel Yokes or Steel Laminated Yokes
Laminated Steel Yokes

Joining Methods Glued / Welded / Combination of gluing and welding

Gluing is generally used for magnets that are < 0.5 meter in length

Longer dipole magnets are more suited to a welded construction

Trying to glue dipole magnets that have a long length to yoke cross
section ratio is very difficult to accomplish and stacking curved
dipole magnets adds yet another level of complexity
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Magnet Yoke Fabrication

Solid Steel Yokes or Steel Laminated Yokes
Cost Comparison
Typical undocumented studies have shown that the cost of fabricating a few ( 4)
laminated magnet yokes is dominated by the tooling costs and exceeds the cost of
machining the same number of yokes from solid blocks. However, these same
studies have shown that the cost of machining exceeds the cost of fabricating
laminated cores for the typical accelerator application where the tooling costs can
be shared by the larger number of core segments. (J. T. Tanabe)
If secondary machining is required to achieve high mechanical precision
the cost advantage offered by laminated yokes is lost
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Manufacturing Process Comparison

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Magnet Yoke Fabrication

Preparing Laminations for Stacking and Bonding

Unclean laminations will result in poorly bonded yokes

Laminations contaminated with stamping lubricants or cutting oils and

handling laminations with bare hands that can leave dirt and oily finger
prints on the surface

Important to handle the laminations wearing clean lint free gloves and
cleaning the laminations prior to stacking using a recommended or
proven cleaning method
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Magnet Yoke Fabrication

Preparing Laminations for Stacking and Bonding

Burrs on lamination cut edges and other defects (bent or creased

laminations) will result in poorly bonded yokes with low and inconsistent
packing densities

Indications of these defects can generally be observed on the outer

surface of the yoke at the un-bonded area

Incorporate a visual inspection of laminations a deburring process

and a sorting procedure to ensure that defective laminations do not end
up in the stacked yoke
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Magnet Yoke Fabrication

Yoke Stacking / Bonding Fixture

Stacking fixtures that do not apply an evenly distributed pressure

across the entire yoke and a constant pressure throughout the bonding
cycle will result in poorly bonded yokes

Some stacking fixtures had to be modified to incorporate the following

standard practices and features

A) Engineered to be sufficiently rigid so that it will not deflect or deform

under the applied forces
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Magnet Yoke Fabrication

Yoke Stacking / Bonding Fixture
B) The clamping arrangement must apply a uniform pressure
across the entire yoke

Provide as many clamping positions as possible

Ideally located directly over the laminations or at least as close

as possible to the laminations

Positioned in a symmetrical arrangement

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Magnet Yoke Fabrication

Yoke Stacking / Bonding Fixture
C) Belleville washers are used to apply a constant pressure throughout
the bonding cycle
D) If top and bottom yoke halves are stacked at the same time using the
same fixture Stacking the laminations in series generally has better
results than stacking them side by side
E) Registration surfaces must be smooth and coated with a molybdenum
based lubricant to minimize frictional forces (Molykote leaves no trace
of contamination)

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Magnet Yoke Fabrication

Yoke Bonding

Optimized bonding conditions (pressure , time and temperature) are

paramount in producing strongly bonded yokes

Material manufacturers generally give a broad range for the bonding

conditions The optimized conditions are dependent on the actual yoke
size and geometry as well as the method of heating

Optimized conditions are best developed through the use of engineering

analysis that take into account the following considerations

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Magnet Yoke Fabrication

Yoke Bonding
Applied Pressure

Stay within the material manufacturers recommended range for

applied pressure if possible

Pressure measurement film is an accurate and visual representation of

the pressure distribution that is being applied to the yoke by the
stacking fixture under actual conditions at room temperature

Applied pressure should be maintained for as long as possible during

the yoke cool down period
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Magnet Yoke Fabrication

Yoke Bonding
Time and Temperature

Analysis should be performed to determine the heating profile

(ramp-up rate, maximum temperature, soak time, and cool-down
rate) using the actual geometry and mass of both the yoke plus
the stacking fixture

For the most accurate readings Thermal couples used to

monitor the yoke temperature are attached as close as possible to
the center of the yoke
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Magnet Yoke Fabrication

Packing Density

A packing density greater than 98% with less than a 0.2%

variation between the top and bottom yokes is required for high
precision quality magnets

Magnet asymmetries caused by a variation in packing density

between the top & bottom yokes can often cause disturbance to
the field as a result of a displacement between the mechanical
and magnetic centers

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Magnet Coil Fabrication

Vacuum impregnation of the coils and the use of a potting mold was
specified in order to accurately produce the coils final shape and close
mechanical tolerance requirements for

Coil installation onto the poles

Providing the clearance necessary for installation of the vacuum
chamber and other components

Solutions to production issues that were encountered during coil

fabrication are shown on the next three slides

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Magnet Coil Fabrication

Coil Preparation Prior to Potting

Preformed G10 reinforcement blocks are used to provide the structural

support necessary to strain relieve the conductor leads as they exit the
encapsulated coil assembly The conductor and reinforcement block
must be secured to the coil assembly using fiberglass tape

A ground wrap of fiberglass tape is wound around the completed coil

assembly securing its shape during potting

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Magnet Coil Fabrication

Coil Potting Mold

Coat the inside surfaces of the mold cavity with a mold releasing agent
to facilitate the removal of the cured coil

G10 strips are used to center the wound coil within the mold allowing
the epoxy to flow uniformly around the entire coil assembly

Large molds containing cavities for multiple coils to be potted

simultaneously can potentially cause problems trying to fill all of the
cavities in the allotted time before the epoxy starts to cure
Magnet Production Workshop April 11-12, 2012
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Magnet Coil Fabrication

Coil Potting (Encapsulation) Process
Vacuum impregnation of the coils

In order to completely evacuate air from the mold cavity The vacuum
pump draws the mixed epoxy into the cavity from the bottom of the
mold completely fills the cavity and exists through the top of the
mold

Alumina filled epoxy resin prolongs the life of the coils by providing
added radiation resistance Getting the mixture to flow uniformly
through the mold cavity proved to be a challenging task for most until
the exact recipe (alumina particle size, mixing time and temperature)
was established
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Magnet Assembly
Secondary Processing
Small variations during fabrication and assembly have
an adverse effect on magnet performance and
repeatability.
Reducing these variations to an acceptable level
requires secondary processing of the magnet after
bonding and assembly.

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Magnet Assembly
Secondary Processing
To achieve the high precision quality requirements of the magnetic field
and to ensure repeatable magnetic performance after disassembly and
reassembly of the magnet

Machine the mating registration surfaces of each yoke half and each
mid-plane spacer

Assemble yoke halves using a documented bolt tightening sequence

and torque procedure

Best magnetic field quality results are achieved when the pole profile is
machined in the assembled magnet
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Manufacturing Process Comparison

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Acknowledgements

THANKS TO THE BNL MAGNET TEAM

AND
OUR INDUSTRIAL CONTRACTORS
AROUND THE WORLD

Lessons Learned Workshop, April 11-13, 2012

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