4) SOW M1 Flexure AL-1567-0364A.pdf

SOW: M1 Flexure for ALS-U Beamlines

Kyle La Fleche

Release Date: Aug 9 2022 10:06:44 AM PDT

Document Number: AL-1567-0364 Revision: A

Document Status: Released Document Type: QUALITY ASSURANCE

Category Code: AL7801

ALS-U - INSERTION DEVICE BEAMLINES

QA

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Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

All officially released LBNL documents are watermarked and contain LBNL Document Control Center release information in the lower-left corner of the document's pages.

Printed hard copies of this document are for reference only.

Table of Contents

Revision History

Approvals

Abbreviations and Acronyms

1 Applicable Documents

2 Introduction

2.1 Project Overview

2.2 Description of Items

2.3 Roles and Responsibilities

3 Scope of Work

4 Deliverables and Schedule

4.1 Prototype flexure

4.2 Production series

5 Management

5.1 Kick-off meeting

5.2 Reporting/Communication requirements

5.3 Documentation requirements

5.4 Reviews

5.5 Hold points

6 Fabrication

7 Shipping

8 Quality Assurance

8.1 Quality reporting requirements

8.1.1 Subcontractor quality program

8.1.2 Deviation requests

8.1.3 NCR

8.2 Factory Inspection and Test Plan

8.3 ACL

9 References ci al ly R el ea se d to th e

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REVISION HISTORY

Rev. CM Number Description of Change A AL-1567-0364 Initial Release ci al ly R el ea se d to th e

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APPROVALS

The following individual(s) shall approve or review this document:

Approver/Reviewer Project Role Elaine DiMasi ALS-U Beamlines System Manager TBD ALS-U ID Beamlines Control Account Manager Arnaud Allézy Senior Mechanical Engineer Maxime Bergeret Lead Beamline Engineer ci al ly R el ea se d to th e

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ABBREVIATIONS AND ACRONYMS

ACL Acceptance Criteria List ALS Advanced Light Source ALS-U Advanced Light Source Upgrade CAD Computer Aided Design CMM Coordinate Measuring Machine DCC Document Control Center DoF Degree of Freedom GD&T Geometric Dimensioning and Tolerancing HHLO High Heat Load Optic LBNL Lawrence Berkeley National Laboratory MBA Multibend Achromat NCR Nonconformance Report NTP Notice to Proceed QA Quality Assurance QAP Quality Assurance Plan RFP Request for Proposal RGA Residual Gas Analysis SOW Statement of Work UHV Ultra High Vacuum University The Regents of the University of California ci al ly R el ea se d to th e

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1 APPLICABLE DOCUMENTS

This section identifies applicable documents that are considered to be a part of this document. All information contained in an applicable document shall be valid to the full extent, unless specifically noted within this document. Applicable documents shall be obtained from the LBNL DCC.

Number Rev. Title AL-1009-9880 B ALS-U Units Policy and Units Definition AL-1208-0209 B ALS-U supplier quality evaluation survey AL-1220-7841 E UHV Chamber and Component Production Requirements AL-1418-3364 B M1 Pitch/Roll Flexure – Middle Flange Mounting AL-1567-1043 A ACL: M1 Flexure for ALS-U Beamlines ci al ly R el ea se d to th e

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2 INTRODUCTION

2.1 Project Overview

ALS-U is an upgrade project to the LBNL Advanced Light Source (ALS). The ALS is a 1.9 GeV storage ring operating at 500 mA of beam current. It is optimized to produce intense beams of soft x-rays, which offer spectroscopic contrast, nanometer-scale resolution, and broad temporal sensitivity. The ALS facility includes an accelerator complex and photon delivery system that is capable of providing the foundations for an upgrade that will achieve world-leading soft x-ray coherent flux. The existing ALS provides a ready-made foundation, including conventional facilities and also includes extensive beamlines (up to 40 simultaneously operating beamlines) and instrumentation, an experimental hall, computing resources, ancillary laboratories, offices, and related infrastructure that will be heavily utilized in an upgrade scenario.

The ALS will be upgraded with a MBA lattice design that will provide a soft x-ray source that is orders of magnitudes brighter — an up to 100-1000 times increase in brightness and will provide a significantly higher fraction of coherent light in the soft x-ray region than is currently available at ALS.

Any resulting Subcontract will be between the University and the party identified as the Subcontractor and will be issued under Prime Contract No. DE-AC02-05CH11231 between the University and the United States Government (hereinafter “U.S.

Government”), represented by the Department of Energy (hereinafter “DOE”) for the management and operation of LBNL and the performance of research and related work.

2.2 Description of Items

The purpose of this statement of work is to define the production process for the M1 Flexure. The M1 Flexure (henceforth referred to as the “flexure”) is a monolithic, flexible, metal component made entirely of improved strength titanium 662. Its primary purpose is to provide mounting for the HHLO and rotational motion in two DoF to position the x-ray beam with respect to downstream optics. A linear actuator for each DoF – pitch and roll - is coupled to the flexure and provides the force necessary to rotate through each of the flexure’s full ranges. Web elements machined directly into the flexure geometry are designed to bend under the actuator force providing repeatable rotations with minimal parasitic motion in other DoFs. This is accomplished through optimized design of the web features such that the bending motions occur entirely within the titanium’s elastic region.

As a result, the flexure is essentially a zero-backlash mechanism that can operate for tens of thousands of cycles before failure is expected making it ideal for the small, extremely precise, motions required for x-ray beam alignment.

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Figure 2.1. M1 flexure ci al ly R el ea se d to th e

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Figure 2.2. M1 flexure shown mounted in the M1 mirror assembly.

2.3 Roles and Responsibilities

Two individuals will be identified in the awarded contract: a University Procurement Specialist and a University Technical Representative. The named university personnel are responsible for the contract administration from award initiation through the receipt and acceptance of the purchased item.

University Procurement Representative – See Subcontract for details.

University Technical Representative – See Subcontract for details.

The selected Subcontractor is required to identify a project manager to act as the single point of contact on the Subcontractor’s team. The project manager interfaces directly with the University Technical Representative for technical, programmatic, and schedule items.

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3 SCOPE OF WORK

The scope of work shall include the manufacture of one prototype and six production, build-to-print, flexures according to drawing AL-1418-3364. The prototype shall be evaluated at LBNL to ensure that it meets performance benchmarks and incorporate design changes if necessary. Design changes resulting from the evaluation will be incorporated into the CAD model and drawing set at the conclusion of prototype testing.

Manufacturing activities will be on hold until the Subcontractor has received the updated design and conducted a Production Readiness Review with LBNL. Following completion of the readiness review and LBNL approval, LBNL will issue a NTP whereupon the vendor may initiate fabrication activities for the additional six flexures in the production series according to the updated CAD model and drawing set.

Each flexure shall be manufactured using improved strength titanium 662 billets supplied by LBNL in accordance with all applicable sections of LBNL’s UHV Chamber and Component Production Requirements, AL-1220-7841. Conformance with flexure drawing dimensions and tolerances shall be summarized in a metrology report and an RGA shall be performed on each flexure produced in accordance with AL-1220-7841, section 14.2, to verify UHV cleanliness before shipping. Data table templates in sections

16.3 and 16.4 shall be used to record RGA instrument information and scan data.

Alternate data recording formats, as proposed by the Subcontractor, may be accepted at LBNL’s discretion.

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4 DELIVERABLES AND SCHEDULE

The Subcontractor shall deliver the items summarized in Table 4.1 according to the schedule defined therein. The schedule information in Table 4.1 is for planning purposes, with the final negotiated schedule to be incorporated into the Subcontract. Start times for the deliveries listed in items 004 – 010 in Table 4.1 are contingent upon timely delivery by LBNL of the titanium billets to the Subcontractor*. Written requests to modify the schedule may be authorized at LBNL’s discretion.

Table 4.1. List of project phases, deliverables, and associated schedule information.

Due date ARO [weeks]

Item Description Prototype Unit #1 Unit #2 Unit #3 Unit #4 Unit #5 Unit #6

Prototype Fabrication

001 Kick-off meeting 2 N/A

002 Initial schedule 2 N/A

003 Progress reports monthly

004 Prototype flexure 20 N/A

005 Prototype metrology report 20 N/A

006 Prototype RGA report 20 N/A

Due date After Receipt of Prototype Flexure [weeks]

Production Series Fabrication

007 Production Readiness Review & NTP N/A 44

008 Production series flexure units 1-6 N/A 48 52 56 60 64 68

009 Production series flexure metrology reports N/A 48 52 56 60 64 68

010 Production series flexures RGA reports N/A 48 52 56 60 64 68

* Prototype and production series billets to be delivered 3 weeks ARO and 44 weeks after receipt of the prototype flexure, respectively ci al ly R el ea se d to th e

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4.1 Prototype flexure

The Subcontractor will deliver the prototype flexure. Upon receipt of the prototype, LBNL will conduct acceptance activities according to ACL: M1 Flexure for ALS-U Beamlines, AL-1567-1043. It will then be placed in LBNL’s test chamber for performance validation. Upon completion of the prototype testing, LBNL will document all findings, address performance issues, and incorporate any design changes into the CAD model and drawing set which constitute the updates. These updates will be sent to the Subcontractor for review at the Production Readiness Review. This is a hold point, as defined in section 5.5, and is subject to a written NTP from LBNL contingent upon completion of the Production Readiness Review.

4.2 Production series

The Subcontractor shall review the updates at the Production Readiness Review with LBNL to provide technical feedback on any design changes and confirm manufacturability. Once agreement on the updates has been reached, they will be submitted to the Subcontractor in the form of a final CAD model and drawing set to be used as the production series flexure design baseline. The Subcontractor shall deliver the remaining six flexures in the production series.

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5 MANAGEMENT

The Subcontractor shall provide all supervision, labor, materials, tools, testing equipment, and all other services to meet the requirements of this Subcontract.

5.1 Kick-off meeting

Upon award of the Subcontract, the LBNL technical representative will contact the selected Subcontractor to set up a project kick-off meeting.

The Subcontractor shall:

- Present its organization and management, core competencies, experience in supplying beamline components for optical systems, operational capabilities and the team assigned to this project

- Propose the manufacturing process with detailed focus on machining operations expected to be used, technical challenges anticipated and potential mitigation strategies to be employed

- Outline the metrology plan including measurement capabilities, instruments to be used, measurement setup strategies, and dimensions to be captured

- Detail the shipping plan including packaging and handling practices to protect the flexure from damage and to maintain UHV cleanliness during transport

LBNL shall:

- Present an overview of the M1 mirror assembly, flexure function, and critical geometry

- Establish the requirements for communication

- Present the LBNL portal that will be used for data exchange and train the Subcontractor in its use

- Provide the lead time and expected delivery date of the prototype billet

5.2 Reporting/Communication requirements

The Subcontractor shall assign a person responsible for the technical execution of the Subcontract and its follow-up, as well as a person responsible for the administrative follow-up, throughout the duration of the Subcontract. They shall be able to communicate in English.

LBNL reserves the right to visit the production site(s) to witness activities. In that case, LBNL will coordinate with the subcontractor prior to the visit.

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The Subcontractor shall make the technical representative assigned above available to answer technical and schedule questions on an as-needed basis. In addition, the Subcontractor shall send a progress report monthly, to be submitted by the 5th of each month. The report shall include:

- Project progress as compared with the expected progress dictated by the schedule

- Issues encountered and solutions proposed

- Information about any risks in failing to fulfil the requested quality or schedule

- Other reports or data as requested by LBNL

- Action item tracking

5.3 Documentation requirements

Upon subcontract award, a Windchill Project portal will be established by LBNL and access provided to the Subcontractor. Windchill will be used as the repository for all documentation, RGA data, certificates of conformance, test results, models, and drawings.

An electronic copy of all required documentation noted in this document is required and shall be transmitted to LBNL via the designated Windchill portal. LBNL document AL-

1265-6612: ALS-U BUILD TO SPECIFICATION CAD MODEL AND DRAWING

REQUIREMENTS, identifies the acceptable file formats and requirements for the final drawings and CAD models.

Acceptable document formats include .docx, .xlsx, and other editable Office file formats or as noted in this document.

The Subcontractor shall comply with professional and/or LBNL’s standards/codes in matters of document editing, design/drawing process, design reviews and approval, naming conventions and tagging, quality assurance/control, etc. The Subcontractor may propose other design standards, subject to prior written approval by LBNL. LBNL reserves the right to disallow the use of certain codes or norms.

5.4 Reviews

The LBNL technical representative will work with the Subcontractor to establish an appropriate timeline and location for all reviews. At the discretion of LBNL, reviews may be conducted at either the Subcontractor’s, the LBNL site, or via web/video conference tools. External, non-LBNL, reviewers may be included at LBNL’s discretion by providing the Subcontractor with at least 5 days advanced notice.

The following review is required for this project:

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5.5 Hold points

Written approval from LBNL is required to proceed beyond any identified hold points.

The single hold point in the scope of this project occurs at the conclusion of prototype fabrication. The Subcontractor shall cease manufacturing activities after the prototype flexure is shipped and await direction from LBNL at the conclusion of prototype testing, within 44 weeks after receipt of the prototype flexure. At this time, the updated CAD and drawing set will be transmitted to the Subcontractor for review at the Production Readiness Review. Production series manufacturing activities may commence upon successful completion of the readiness review, pending a written NTP from the LBNL technical representative.

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6 FABRICATION

The prototype and subsequent six production flexures shall be machined from LBNL supplied, improved strength, Ti 662 billet. The Subcontractor may use any combination of the machining methods listed in section 8 of AL-1220-7841 to produce optimal flexure geometry consistent with drawing GD&T. The Subcontractor shall have a thorough knowledge of precision engineering, UHV, machining, welding, and controls. It is the responsibility of the Subcontractor to guarantee that the final component geometry meets the dimensions and tolerances specified in drawing AL-1418-3364.

The Subcontractor shall deliver:

- One prototype flexure manufactured according to the specifications contained in drawing AL-1418-3364

- Six production flexures according to the specifications contained in the updated version of the CAD model and drawing, AL-1418-3364, to be submitted for review at the Production Readiness Review.

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7 SHIPPING

Upon completion of manufacturing activities including metrology measurements, UHV cleaning, and RGA scanning, the Subcontractor may initiate the shipping process. The Subcontractor shall be responsible for shipping all units to LBNL. The Subcontractor shall submit a shipping plan at the kick-off meeting. It shall include detailed information about the packaging materials, crates or other containers, and labelling, in accordance with the following requirements:

- Shipping of the flexures shall meet the requirements listed in AL-1220-7841

- Shims or other means of arresting flexure stage rotation shall be implemented to prevent damage to the flexure webs during transport

- The shipping containers shall be reusable (e.g. 4-panel hinged crates)

- All shipping container materials shall meet or exceed the quality standards for Wood Groups II, III, or IV per ASTMD6199

- The shipping containers shall have markings that clearly indicate tie-downs, lifting points, and mass/weight

- The shipping containers shall have markings that clearly indicate the presence of fragile contents

- The project name and contract information shall be attached to the exterior of the shipping container

- The shipping containers shall have soft-adhesive shock indicators (e.g.

Shockwatch®) inside and outside

Shipping shall be accomplished via airfreight. LBNL may approve the shipment of more than one flexure in a shipping container.

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8 QUALITY ASSURANCE

8.1 Quality reporting requirements

8.1.1 Subcontractor quality program

The Subcontractor shall complete the ALS-U Supplier Quality Evaluation Survey, AL- 1208-0209, during RFP. The Subcontractor shall maintain and apply an effective QA program for the design, manufacture, testing of all systems and equipment provided.

Post-award surveys may be required and shall be supported.

8.1.2 Deviation requests

Any deviations from the dictating LBNL documents must be requested by the Subcontractor and approved by LBNL prior to implementation. LBNL will provide a standard deviation request form however, a Subcontractor’s existing or internal document may be utilized with LBNL approval.

Deviation requests apply to requests to modify processes or documented drawings.

Deviation requests DO NOT apply to hardware that is built and does not conform to the specification.

8.1.3 NCR

A NCR provides a summary for products or procedures which do not conform to the defined requirements. Nonconformances may be determined and reported by either the Subcontractor or LBNL staff. LBNL will provide a standard nonconformance report form however, the Subcontractor’s existing or internal document may be utilized with LBNL approval. Nonconformance reports are to be submitted to LBNL within 3 business days of the identification.

NCRs apply to hardware that is built and does not conform to the specification(s). LBNL will provide a written disposition establishing a path forward for each nonconformance.

No operations may be performed on the nonconforming item without LBNL’s written disposition or approval to proceed.

8.2 Factory Inspection and Test Plan

In lieu of an Inspection and Test Plan, the Subcontractor shall provide a metrology report and RGA report with each flexure delivered to verify the dimensions and tolerances specified in drawing AL-1418-3364 and to show that UHV cleanliness standards have been met, respectively.

The metrology report shall:

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- Contain a summary of the manufacturing methods and process used to fabricate the flexure

- Identify and describe, with photographs and/or other visual aids (e.g. drawings), the geometry being measured and the measurement equipment used, including model number, and calibration certification and date

- Present a summary of the results including measurement of the critical geometry agreed upon at the kick-off meeting and detailed explanations for any nonconformance issues

The RGA report shall:

- Be conducted according to section 14.2 of AL-1220-7841

- Include values for the parameters specified in the tables in sections 16.3 and 16.4 of AL-1220-7841

8.3 ACL

AL-1567-1043 lists the LBNL acceptance criteria to be executed upon receipt of each article.

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9 REFERENCES

Items listed in this section are to be used to provide references for industry, manufacturing, and QA standards or other source material for additional context with regard to specifications listed in this document.

Number Title

ASTMD6199 Standard Practice for Quality of Wood Members of Containers and Pallets

ISO 90001:2000 Quality management systems — Requirements ci al ly R el ea se d to th e

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9 References