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Manufacturing and Quality Assurance: Magnet Production Workshop
Manufacturing and Quality Assurance: Magnet Production Workshop
MATERIAL
• Ideally all magnets from the same family are manufactured from a single
batch of steel (same heat)
• Gluing is generally used for magnets that are < 0.5 meter in length
• 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
• Important to handle the laminations wearing clean lint free gloves and
cleaning the laminations prior to stacking using a recommended or
proven cleaning method
Magnet Production Workshop – April 11-12, 2012
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BROOKHAVEN SCIENCE ASSOCIATES
Magnet Yoke Fabrication
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
Yoke Bonding
Applied Pressure
• Stay within the material manufacturer’s recommended range for applied
pressure if possible
Packing Density
• 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
• 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
• 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
Secondary Processing
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
• Best magnetic field quality results are achieved when the pole profile is
machined in the assembled magnet
Magnet Production Workshop – April 11-12, 2012
26
BROOKHAVEN SCIENCE ASSOCIATES
Manufacturing Process Comparison
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