| Paper | Title | Page |
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| MOP038 | Series Production of EXFEL 1.3 GHz SRF Cavities at E. Zanon: Management, Infrastructures and Quality Control | 194 |
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| In this paper we report on the capability of Ettore Zanon S.p.A. (EZ) to implement a EXFEL 1,3 GHz SRF cavities production system. In order to assure the series efficient repeatability of the product, this system is based on work team, composed of people with different skills, qualified infrastructures and technical procedures. A detailed study of the different work phases of the production cycle has been performed in advance, highlighting the technical difficulties and the production constraints. Based on this result, infrastructures and processes have been optimized to grant the specified quality and time/cost requirements and procedures and operating instructions, where the most complexes and delicate phases as well as the responsibilities and acceptance criteria are investigated, have been introduced. Qualification operations and eight pre-series cavities have proven EZ capability of fulfilling the imposed requirements. The above described manufacturing system allows nowadays a production rate of 4 cavities per week. EZ future developments involve minimizing time and costs while keeping the highest quality standard. | ||
| MOP042 | Quality Control and Processes Optimization for the EXFEL Superconducting Cavities Series Production at Ettore Zanon spa | 208 |
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| The construction of the European XFEL forced the first mass production of Niobium bulk SRF cavities. In this context Ettore Zanon S.p.A. built a fully new facility designed to produce four fully treated and He tank equipped cavities per week, ready to be tested at DESY. The facility already reached the foreseen production rate. The guarantee of the highest quality of the resonators produced requires a very strict quality control plan. At the same time, the requirements of the industrial production in terms of time, cost and productivity must be satisfied. As a consequence processes must be standardized and working times optimized. In the following, after the description of the production facility, we would like to highlight and discuss the strategies and arrangements adopted in the various critical fields (clean room, vacuum, etc.) to ensure the foreseen results. Moreover correlation between cavities performances and production cycle parameters will be investigated and discussed. | ||
| TUP056 | Industrialization of European XFEL Preparation Cycle “BCP Flash” at Ettore Zanon Company | 547 |
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In the Specification for XFEL Cavity preparation (R1) two different preparation sequences are presented. Ettore Zanon Company as one of the two companies contracted for XFEL cavity production and preparation has chosen the so called BCP flash cycle. To fulfill the requested work flow and quality of infrastructure and processes, the company set up a complete new infrastructure in refurbished fabrication halls. The layout of the facility, set up of work flow of preparation and test results of resonators processed by E.Zanon in their infrastructure will be reported.
(R1) Series Surface and acceptance test preparation of superconducting cavities for the European Xfel (XFEL/A - D) JUNE 30, 2009 |
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| TUP062 | Application of In-Vacuum Infrared Pyrometry During Fabrication of European XFEL Niobium Cavities | 570 |
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| A technique to measure the temperature of Niobium components in vacuum during Electron Beam Welding (EBW) operation is presented and results obtained on the large scale cavity production for the European XFEL are discussed. During the EBW process, the knowledge of the components temperature during the welding operation could help both for the better choice of the welding parameters and for the optimization of the production cycle. In collaboration with the Italian firm Ettore Zanon (EZ), we developed a system able to measure the temperature of Nb components in vacuum during EBW operation using a IR pyrometer placed outside the vacuum chamber through an appropriate vacuum viewport. In the paper the experience of this device during the production of Nb components for the XFEL 1.3 GHz cavity production is discussed. | ||