Klystron and Microwave Department Capabilities and X-Band Klystron Overview

Klystron and Microwave Department Capabilities and X-Band Klystron Overview January 5, 2011 Erik Jongewaard KMD and X-Band Overview Slide 1 KMD Ov...
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Klystron and Microwave Department Capabilities and X-Band Klystron Overview

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 1

KMD Overview

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 2

KMD Overview • Staff – 12 Engineers / Physicists – 31 Technicians – 7 machinists, 2 mechanical designers, 2 support personnel, and one administrative assistant

• Facilities – Klystron Test Lab Highbay • ~22500 sq ft

– B44 First floor • ~13125 sq ft

– B44 Second Floor • ~5625 sq ft

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 3

KMD Overview • Four Groups: – Manufacturing • Design, assembly, machine shop, QC, brazing, coatings, vacuum processing

– RF Engineering and Accelerator Maintenance • LLRF design, RF systems upgrades (AIPs), SLAC RF systems maintenance

– Tube R&D • RF, magnetostatic, e-beam, and RF/e-beam interaction simulations and design

– Klystron Test Lab • 10 High Power Pulsed Modulators and two High Power CW Test Stands January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 4

Machine Shop: In-process Machining

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 5

Quality Assurance/Metrology

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 6

Tube Shop

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 7

Hydrogen Furnace Brazing

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 8

Cathode Processing

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 9

Vacuum Processing

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 10

West Side of Test Lab Odd Numbered Test Stands

PEP II RF Bunker

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 11

Even Numbered Test Stands

Klystron Test Lab- East Side

ASTA Bunker

SLED Delay Lines

Sub-booster Test

Weld Room

Dress Area

Thyratron Test Stands

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 12

5045 Klystron SLAC linac RF source, in continuous production since 1983. To date 1113 tubes have been produced with a current MTBF of over 60k hrs and 20 tubes still running with over 100k hrs of filament time. Current yield is 100%. Specs: Operating frequency: 2.856 GHz Power output: 65 MW peak, 45 kW average Focusing: Solenoid

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 13

B-Factory Klystron PEP-II storage ring (B-Factory) RF source. Designed in cooperation with CPI under a CRADA. Prototype completed in 1994. To date 12 tubes have been produced and tube S/N 1 has over 42k filament hrs. Specs: Operating frequency: 476 MHz Power output: 1.2 MW CW Focusing: Solenoid

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 14

150MW Klystron (DESY)

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 15

XL-4 Klystron X-band source tube for NLCTA, ASTA , LCLS, and RF breakdown experiments. Last iteration of a line of 100 and 50 MW solenoid focused tubes. To date 15 tubes have been produced with several tubes having over 10k hrs of filament time. Specs: Operating frequency: 11.424 GHz Power output: 50 MW peak, 9 kW average Focusing: Solenoid

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 16

XL5 Klystron • • • • • • • •

January 5, 2011 Erik Jongewaard

Tubes for PSI, Trieste & CERN XL4 variation to higher freq 11.992 – 11.994 GHz 1.0 – 1.5us 100 - 50Hz 50MW 50MHz 3dB BW 410 - 450kV

KMD and X-Band Overview Slide 17

X-Band PPM Klystron NLC/ILC x-band source prototype. Last of a line of 50 and 75 MW PPM focused tubes for the room temperature NLC/ILC design. Specs: Operating frequency: 11.424 GHz Power output: 75 MW peak, 13.5 kW average Focusing: Periodic Permanent Magnet

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 18

W-Band Sheet Beam Klystron W-band sheet beam klystron prototype. Proofof-principal test of sheet beam transport and RF interaction. Specs: Operating frequency: ~95 GHz Small signal gain: 31db Focusing: Periodic Permanent Magnet

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 19

Components

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 20

LCLS RF Gun

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 21

LSBK Diode at TS02

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 22

LCLS XL-4 Klystron

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 23

X-band Accelerator Structure

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 24

LCLS RF Phase Cavities

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 25

PEP-II RF System Control Racks

Load Circulator

Penetration

1.2 MW Klystron

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 26

PEP Transverse Feedback

LBNL New Digital Delay New Measurement System January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 27

New Kicker Electrodes

PEP-II Longitudinal Kicker HFSS

Measured

Frequency (GHz)

1.071

1.074

Bandwidth (MHz)

224

216

Loaded QL

4.78

4.97

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 28

SPEAR 3 RF Station Single klystron four cavity station

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 29

Spear 3 RF Distribution and Bucket Select System Electronics to inject into any of the 476.3MHz SPEAR ring buckets from the 357MHz Booster ring.

195

Scope Trace

200

179

150

150

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100

50

Degrees

Degrees

50

ScopeData k

Scope Trace

200

0

ScopeData k

0

50

50

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100

150

150

192

174 200 0

5 1 .10

5 2 .10

5 3 .10

0

5 4 .10

5 5 .10 T imeScale k T ime

5 6 .10

5 7 .10

5 8 .10

5 9 .10

4 1 .10 5

9.999 .10

Switching – Not Phase Continuous January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 30

200 0

0

0.002

0.004

0.006

0.008

0.01

0.012

0.014

0.016

T imeScale k T ime

Switching – Phase Continuous

0.018

0.02 0.02

SLAC Main Drive Line Phase Noise Old Oscillator

New Oscillator

Noise Floor -120dBc/38Hz = -136dBc/Hz = 120fS rms Jitter in 5MHz BW

Noise Floor -143dBc/38Hz = -158dBc/Hz < 16fS rms Jitter in 10MHz BW

New Oscillators Have a noise floor of -157dBc/Hz @ 476MHz January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 31

E-163 RF Systems

Low Noise Frequency Generation Chassis Laser Oscillator Noise Spectrum Firsts tests to show that Lasers can be locked to RF with less than 0.5ps rms jitter.

900W S-Band Solid State Amplifier January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 32

LCLS RF System 0.1ps rms Stability

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 33

LCLS LLRF Systems

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 34

X-Band Klystron Overview

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 35

Brief History X-band klystron work began at SLAC in the mid to late 80’s to develop high frequency, high power RF sources for the linear collider designs under consideration at that time. This lead to a long lineage of x-band klystrons: the XC, XL, and PPM series, and most recently, the XL5 (a total of 40+ klystrons and diodes built to date).

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 36

The XC Series • Goal: 100 MW,1μs pulse length at 440 KV and 520 A (K=1.8 μP) • Eight tubes were built exploring: – Output cavity designs (seen at right) • Single cell, 2 cell CC, 4 cell TW, 2 independent cell, 4 cell SW

– Output window design • Thin pillbox, thick pillbox, none

– Beam focusing and transport

• All of the tubes suffered from RF breakdown prior to reaching design power and pulse length

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 37

The XL Series • Drawing on the XC experiences the XL series was launched to produce RF sources for the NLCTA. • Goal: 50 MW, 1.5µs 440kV at 350 A (K=1.2 μP) – Used single TE01 output window – Used multi-gap outputs (SW and TW)

• Design goals achieved with the fourth tube in the series, the XL4 (4 cell TW output and gun ion pump) January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 38

XL4 • This is our current “work horse” x-band RF source – 18 tubes built to date (not counting rebuilds) – Four in use in the KTL to feed the ASTA bunker (TS-06 and TS08) and HGB experiments at TS-02 and TS-04 – Seven sockets in ESB, five for NLCTA and a two-pack socket (not all occupied currently) – One tube and spare for LCLS linearizer, more contemplated for deflector structure installation and future injector(s)

• Incremental design improvements – Larger TE01 output window from PPM tube work – Large radius coupling cell irises from XL5 work

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 39

The XL Series Output Power vs Beam Voltage for the XL4 Klystrons 100 XL4-2 (1.5 microsec) XL4-1 (1.5 microsec.) XL4-1 (1.2 microsec.)

80

(100 ns.)

60

40

20

0 250

300

350

400

450

500

Beam Voltage (KV) aev-3/24/97

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 40

The PPM Series • For the large linear collider RF systems under consideration, it was clear that the power hungry XL series solenoids had to be eliminated. This lead us to investigate PPM (or more accurately PCM) focused klystrons. • XL-PPM, 50 MW, 1.5 μs, K=.6 μP design – One diode, one klystron built, achieved: 50 MW at 2.4 μs and 120 Hz for two minute bursts (heating and x-ray limited)

• XP1: 75 MW with K=.75 μP design – One klystron built, achieved: 79 MW at 2.8 μs, limited to 10 Hz due to body heating

• XP3: 75 MW, 1.6-3.2 μs, K=.75 μP design – One diode, five klystrons built, achieved: 75 MW at 1.62 μs and 120 Hz

• Work terminated when cold ILC decision was made

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 41

XP3-1 With Clamp-on Magnets

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 42

XL5 • During 2008 and 2009 MOUs were established between SLAC and three European labs (CERN, PSI, and ST) for the development and fabrication of a 50 MW 12 GHz klystron scaled from the XL4 (total of five tubes) • Design features – Uses XL4 beam optics (same gun, solenoid, collector) – Keeps XL4 cavity spacing to allow maximal part commonality – Scale cavities and other frequency dependent parts only (output, mode converter, windows)

• First three tubes tested, the first has been shipped and installed at CERN. The last two awaiting bake. • Testing progressing well after reconfiguring customer supplied RF load hardware. January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 43

XL5 Simulations

60 55 50 45 40 Gain (purple) and MW out vs input (blue) - AJDSK runs of the XL5 design at 420kV and MAGIC (yellow)

35 30 25 0

200

January 5, 2011 Erik Jongewaard

400

600

800

1000

KMD and X-Band Overview Slide 44

XL5 Klystron This is a 50MW Klystron not 60MW!

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 45

XL5 Processing Baseline rf fwd and reflected from the coupler after the output window (downward slope is due to instrumentation). Example of breakdown downstream of the coupler (load side, the more common event). Example of breakdown upstream of the coupler (tube side) during processing. January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 46

XL5-1B 2010 Processing 9-21 to 9-27 9-28 to 10-1 10-2 to 10-2 10-3 to 10-7

Performance

DC beam processing to 410kV full pulse width rf processing to 50MW 1500ns (4.5kW) rf processing to 60MW 1500ns (5.4kW) Post rf processing and measurements

70

6000

Average rf, Watt

MW at max drive (~630W) vs. kV beam

60 50

4000

40 30

2000

20 10

0

0 09/21

09/23

09/27

09/29

10/01

10/03

10/05

10/07

FWHM = 1.8us, 2.3us, 2.8us, 3.2us

600

Beam kV

09/25

250

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MW out vs. W in at 411kV

70 60 50 40

400

30 20

200

10 0

0 09/21

09/23

09/25

09/27

09/29

10/01

10/03

10/05

10/07

0

200

50MW * 1500ns = 75 J 60MW * 1500ns = 90 J

400

600

800

GAIN at 20MW output across 90MHz band

100

Joules per pulse

350

56.0 55.5 55.0

50

54.5 54.0 53.5

0

53.0 09/21

09/23

January 5, 2011 Erik Jongewaard

09/25

09/27

09/29

10/01

10/03

10/05

10/07

KMD and X-Band Overview Slide 47

11940

11960

11980

12000

12020

12040

12060

XL5 50MW Breakdown Rate • • • • •

Matched load, RF fwd/refl trigger interrupt system XL5-1A: (very hard to say, no coupler) 1 per hour. XL5-2A: (hard to say, no coupler) 1 per 12 hours. XL5-3A: 0 per 24 hours. XL5-1B: After processing, and for operation at ≥50MW at 60Hz for at least 7 hours we detected no rf breakdown in the tube (any disturbances of the rf were after the external output rf coupler)…or…0 breakdowns per 7 hours.

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 48

X-band Klystrons Today • Building five XL5s for European labs • Building one XL4 for BNL • Building one XL4 now for the LLNL Megaray Program, another to follow. • Plans underway to industrialize the XL4 klystron – Participated in x-band technology workshop to spark interest in x-band technology – Provided drawings/fabrication documentation to microwave tube vendors – Purchasing sample klystron(s) from tube vendor(s) – Purchased focusing solenoid from outside vendor January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 49

Conclusion • Rich history of x-band klystron development • Still working on improving devices • Increasing interest domestic and internationally with x-band technology • New applications arising at SLAC each requiring a new XL socket – LCSL II injector – X-band deflector

• The future looks bright for x-band RF

January 5, 2011 Erik Jongewaard

KMD and X-Band Overview Slide 50