Statement of Work (SOW).pdf

Foil Beam Chamber Assembly Development – Tensioned Foil Test Samples

Argonne National Laboratory (ANL) Point of Contact (POC): Joel Fuerst Period of Performance: TBD

Abstract – This document describes the initial development work required to demonstrate ultrasonic welding as a viable fabrication technique for thin-wall foil vacuum chambers. The vendor is tasked with producing test samples that yield flat, tensioned foils attached to a bulk copper substrate. Leak tightness will be evaluated by ANL upon delivery.

Table of Contents

Scope of Work

Background

ANL-Supplied Material

Deliverables

Production Strategy

Production Samples

Scope of Work

The scope of work to be performed by the vendor consists of the following:

1. Receipt and acceptance of ANL-supplied 110ETP copper bulk copper samples and foil stock.

2. Fixturing and ultrasonic welding of 100-micron thick 110ETP copper foils to top and bottom of the copper samples along both the length and width (full perimeter).

3. Foils shall be tensioned as required to maintain a flat, wrinkle-free foil surface after welding.

Revision Date Reason 0 01/31/2024 Original 1 04/08/2024 Revised bulk copper sample width from 1.5” to 3”

Statement of Work

SOW for Superconducting Undulator Magnet Assemblies

Background

In December of 2023, a series of tests were conducted at Branson using short (12”) copper frames and 0.004” (100 micron) foils of 110ETP copper (Figure 1). The purpose of these tests was to evaluate the leak tightness of the ultrasonic welds. No particular effort was made to tension or otherwise stretch the foils to achieve flat chamber surfaces.

Evaluation of the welded samples at ANL highlighted the importance of controlling foil flatness to achieve a useable result.

Figure 1: test frames (left), welding in progress (center), practice welds (right)

ANL-Supplied Material

ANL will provide machined 110ETP bulk copper samples and 110ETP copper foil 0.004” (100 micron) thick.

Samples are 6” x 0.75” x 3” with 1/8” dia rounds (Figure 2). Samples with and without a leak checking hole will be provided. Round size can be adjusted if required.

Fig. 2-Left: sample after welding Fig. 2-Right: welded sample drilled for leak checking (by ANL)

Deliverables

Production Strategy Branson will evaluate the scope and provide a work plan to achieve flat welded foils. The strategy should include an estimate of the number of bulk copper samples and foil length required to demonstrate success.

Production Samples Finished samples will be shipped to ANL for preparation (Fig. 2–Right) and leak check. Leak checking holes will be added to samples without this feature.