Design optimization of the water-cooled coil for the pulsed electromagnetic extraction septum, SMH40.

The septum blade is a 900 mm long, water cooled OFE Cu conductor (operation at 28 kA). It is a critical component of a pulsed magnet (SMH40) used for heavy ion extraction out of the Low Energy Ion Ring (LEIR) in the accelerator complex at CERN. A failure analysis of the currently operational design has shown issues with fatigue due to operational loads, and a brazing defect on the sequential reinforced design. The objective of this bachelor thesis is to analyze and redesign the septum blade, allowing an increased lifetime, optimized manufacturing procedure, and reduced non-conformities. The following list of sub-tasks have been completed to achieve the main objective: 1) Failure analysis including numerical computation (structural mechanics and computational fluid dynamics), non-destructive testing (leak testing and ultrasonic inspection) as well as destructive testing (optical microscopy of a metallurgical cross section). 2) Develop a list of requirements for a new design, based on the functional- and failure analysis. The compliance with this set of requirements is tested on the new design. 3) Production of three vacuum furnace brazed samples to prove a successful leak tight connection with the optimized joint configuration, changed type of brazing filler metal and brazing procedure. 4) A physical prototype to analyse the feasibility of the design.