Undulators for an XFEL Laser
The Summary
Undulators are a key component within photon systems in XFEL’s and synchrotrons. This case study examines a build-to-print project undertaken by our company to machine, fabricate, assemble and integrate a series of undulators for a prominent government laboratory. The primary challenge was the manufacturing of very high-tolerance components, subsequent precision assembly and electro-mechanical integration/test. The successful completion of this project highlights our expertise in large envelope, 5-axis machining and precision fabrication, assembly and electro-mechanical integration.
Background
Insertion devices are an essential component in creating high energy x-ray band light in light sources such as XFELs and synchrotrons. Insertion devices, like undulators, are devices that produce a periodic magnetic field, enabling the generation of synchrotron radiation or free-electron generated coherent light. Keller Technology was tasked to build these undulators to upgrade a current XFEL to a higher energy and higher rep rate machine.
Client Description
Our client is a leading government laboratory with world class particle accelerator based light source user facilities.
Project Goals and Objectives
The primary goal of the project was to fabricate undulators that meet the exact standards required for high-precision photon delivery. Specific objectives included:
- Achieving precise magnetic field configurations.
- Ensuring mechanical stability and durability of the undulators.
- Produce undulators in production quantities in a traceable and systematic manner.
Challenges Faced
The project presented several challenges, including:
Technical Challenges
Achieving the necessary precision in machining the undulator components was critical. High tolerances and extensive in-process metrology was required to ensure overall specifications were met.
Operational Challenges
Maintaining traceability and uniformity was critical. A detailed traveler was utilized to ensure adherence to established processes and document in- process metrology.
Quality Control
Implementing rigorous testing and inspection protocols at each stage of the process to ensure compliance with the client’s specifications.
Technologies such as computer-aided manufacturing (CAM) were integral to our process, allowing us to achieve the high levels of precision required. The use of advanced metrology equipment ensured that all components met the specified tolerances.
Results and Outcomes
The project was completed successfully, with the undulators meeting all performance and quality standards. Key outcomes included:
Enhanced Performance
The new undulators and improvements to the system’s electron accelerator enabled a step change in the machine’s performance.
Client Satisfaction
The client expressed high levels of satisfaction with the project outcomes, highlighting the reliability and performance of the undulators.
Impact on Research
The upgraded beam delivery system has had a positive impact on the laboratory’s research capabilities, facilitating advanced scientific investigations.
Conclusion
The successful completion of this project underscores our expertise in precision machining and fabrication for highly specialized applications. Our ability to overcome technical and logistical challenges and deliver high-quality components on time has strengthened our reputation as a trusted partner for government laboratories and other high-tech clients. This project serves as a model for future initiatives in similar fields, demonstrating the importance of precision and collaboration in achieving outstanding results.
Lessons Learned
Key takeaways from this project include:
- The importance of early and ongoing collaboration with the client to ensure a clear understanding of requirements.
- The need for meticulous planning and coordination, particularly when dealing with specialized materials and tight deadlines.
- The value of implementing rigorous quality control measures throughout the fabrication process.
These lessons will inform our approach to future projects, ensuring that we continue to deliver exceptional results for our clients.