Manufacturing and Quality Assurance: Magnet Production Workshop

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-AC02-
98CH10886

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

2
OUTLINE
• Manufacturing and Quality Assurance Interface
• Build Quality into the Product

• Manufacturing Travelers
• Role of Quality Assurance in Manufacturing
• Magnet Production
• Magnet Yoke Fabrication

• Magnet Coil Fabrication
• Magnet Assembly
Magnet Production Workshop – April 11-12, 2012
3
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

4
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

5
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
6
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

7
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

8
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

9

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

10
Manufacturing Process Comparison
11 BROOKHAVEN SCIENCE ASSOCIATES

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
12
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

13
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

14
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

15
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)

16
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

17
Yoke Bonding
Applied Pressure
• Stay within the material manufacturer’s 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

18
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

19
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

20
Magnet Coil Fabrication
• Vacuum impregnation of the coils and the use of a potting mold was
specified in order to accurately produce the coil’s 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

21
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

22
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
23
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

24
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.

25
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
26
Manufacturing Process Comparison
27 BROOKHAVEN SCIENCE ASSOCIATES

Acknowledgements
THANKS TO THE BNL MAGNET TEAM
AND
OUR INDUSTRIAL CONTRACTORS

AROUND THE WORLD
Lessons Learned Workshop, April 11-13, 2012

28

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Manufacturing and Quality Assurance

Magnet Production Workshop

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

• Manufacturing and Quality Assurance Interface

• Build Quality into the Product

• Magnet Yoke Fabrication

Successful manufacturers build quality into their products

• The quality necessary to achieve the required specification is designed

• This is accomplished through the use of manufacturing travelers,

Magnet Production Workshop – April 11-12, 2012

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

Magnet Production Workshop – April 11-12, 2012

• Provide a systematic and proactive approach for preventing defects

• Implement procedures that ensure manufactured products consistently

• Incorporate the QA requirements into the manufacturing traveler

• Perform audits to ensure:

• Established procedures are being followed

• Shuffling systematically distributes the steel properties among all the

• Sorting ensures that variations in the sheet thickness (caused by

Magnet Production Workshop – April 11-12, 2012

Solid Steel Yokes or Steel Laminated Yokes

Solid Steel Yokes

• 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

Magnet Production Workshop – April 11-12, 2012

Solid Steel Yokes or Steel Laminated Yokes

Laminated Steel Yokes

• Longer dipole magnets are more suited to a welded construction

Magnet Production Workshop – April 11-12, 2012

Solid Steel Yokes or Steel Laminated Yokes

If secondary machining is required to achieve high mechanical precision

the cost advantage offered by laminated yokes is lost

Magnet Production Workshop – April 11-12, 2012

Magnet Production Workshop – April 11-12, 2012

11 BROOKHAVEN SCIENCE ASSOCIATES

Preparing Laminations for Stacking and Bonding

• Unclean laminations will result in poorly bonded yokes

• Laminations contaminated with stamping lubricants or cutting oils and

Preparing Laminations for Stacking and Bonding

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

• Indications of these defects can generally be observed on the outer surface

• Incorporate a visual inspection of laminations – a deburring process – and a

Magnet Production Workshop – April 11-12, 2012

Yoke Stacking / Bonding Fixture

• Stacking fixtures that do not apply an evenly distributed pressure

• Some stacking fixtures had to be modified to incorporate the following

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

Magnet Production Workshop – April 11-12, 2012

Yoke Stacking / Bonding Fixture

B) The clamping arrangement must apply a uniform pressure

• Provide as many clamping positions as possible

• Ideally located directly over the laminations or at least as close

• Positioned in a symmetrical arrangement

Magnet Production Workshop – April 11-12, 2012