A prototype CCT dipole magnet developed by a collaboration between Swedish universities, Swedish industry and CERN will be tested at Uppsala University. This 1 m long double-aperture magnet can provide a field strength of 3.3 T at 85 A in a 70 mm aperture with an integrated field of 2.8 Tm. It is intended to replace the current LHC orbit corrector magnets which are reaching the end of their expected life due to the radiation load. The new magnet is designed to handle the radiation dose of the upgrade to the high-luminosity LHC, which will deliver about ten times the current radiation dose. It must therefore be more resistant to radiation and meet strict requirements in terms of electrical insulation while matching the original field quality and self-protective capability, mechanical volume, and maximum excitation current. This paper will present the latest of the design and manufacturing work, including the results of simulations of the mechanical field and the mechanical stress. Details of the various tests performed before machining the parts are also presented.

Change of relative humidity (RH) in surrounding environment can greatly affect the physical and mechanical properties of wood-based panels. Commercially produced acetylated medium density fiberboard (MDF), Medite Tricoya^®, was used in this study to predict strength and stiffness under varying humid conditions by separating samples in parallel (//) and perpendicular (⊥) to the sanding directions. Thickness swelling, static moduli of elasticity (MOE_stat) and rupture (MOR_stat), and internal bond (IB) strength were measured at three different humid conditions, i.e., dry (35% RH), standard (65% RH) and wet (85% RH). Internal bond (IB) strength was also measured after accelerated aging test. A resonance method was used to determine dynamic modulus of elasticity (MOE_dyn) at the aforementioned humid conditions. Linear regression and finite element (FE) analyses were used to predict the MDF’s static bending behavior. Results showed that dimensional stability, MOE_stat, MOR_stat and IB strength decreased significantly with an increase in RH. No reduction of IB strength was observed after 426 h of accelerated aging test. A multiple regression model was established using MOE_dyn and RH values to predict MOE_stat and MOR_stat. In both directions (// and ⊥), highly significant relationships were observed. The predicted and the measured values of MOE_stat and MOR_stat were satisfactorily related to each other, which indicated that the developed model can be effectively used for evaluating the strength and stiffness of Medite Tricoya^® MDF samples at any humid condition. Percent errors of two different simulation techniques (standard and extended FE method) showed highly efficient way of simulating the MDF structures with low fidelity.

The High Luminosity LHC requires dipole orbit correctors grouped in double aperture magnet assemblies. They provide a field of 3.1 T at 100 A in an aperture of 70 mm. The current standard design is a classical cosine-theta layout made with ribbon cable. However, the electric insulation of this cable is not radiation-resistant enough to withstand the radiation load expected in the coming years of LHC operation. A new design, based on a cable with polyimide insulator, that can replace the existing orbit correctors, is needed. The challenge is to design a magnet that fits directly into the existing positions and that can operate with the same busbars, passive quench protection, and power supplies. The new orbit corrector design meets high requirements on the field quality while keeping within the same mechanical volume and maximum excitation current. A collaboration of Swedish universities and Swedish industry has been formed for the development and production of a prototype magnet following a concurrent engineering methodology to reduce the time needed to produce a CCT magnet. The magnet has a 1 m long CCT dipole layout consisting of two coils. The superconductor is a commercially available 0.33 mm wire with polyimide insulation in a 6-around-1 cable. The channels in the coil formers, that determine the CCT layout, allow for $2\times 5$ cable layers. A total of 70 windings makes that the coil current can be kept below 100 A. We will present the detailed design and preliminary quench simulations.

A newly designed superconducting magnet of the Canted-Cosine-Theta (CCT) type was developed as a result of a collaboration between Swedish universities (Uppsala and Linneaus) and Swedish industries. This magnet was designed to function as a replacement of the present LHC orbit corrector magnets, which are approaching their end of life due to the radiation load. As a result, the new CCT magnet was developed to be more radiation tolerant and to constitute a one-to-one replacement to the currently installed version, which is a 1 m long 70 mm double aperture dipole magnet. The final magnet, which is currently under construction, will be tested at FREIA laboratory at Uppsala University and generate a magnetic field of 3.3 T and an integrated field of 2.8 Tm at about 85 A. To examine the magnet quench behavior and to identify a suitable quench protection system, the 3D electro-magnetic and thermal behavior of the coil was modeled using the RAT-Raccoon software. Based on the simulation results, a Metrosil varistor was selected to protect the magnet during the test. In this article, we report the results of the numerical analysis. The magnet model is equipped with a spot heater to initialize the quench and the temperature and voltages are monitored during the avalanche effect. The simulated current decay and the hot-spot temperature are analyzed with a focus on the impact of quench-back on the magnet protection.

This study investigates the mechanical and physical properties of a wood-based polymer composite DuraSense® 3D S50 Flex K to enhance its potential in large-scale additive manufacturing by studying the influence of printing orientation on the mechanical characteristics of the product. To assess performance, the specimens were produced with different printing layer orientations: at 0°, 30°, 45°, and 90° to the sample length, which corresponds to load application during the tests. Tensile strength, flexural strength, modulus of elasticity, hardness, water absorption, thermophysical properties and microstructure were determined for the samples. The 0° specimens exhibited the highest tensile (15.39 MPa) and flexural strength (26.05 MPa), while the 90° orientation specimens showed reductions in strength of 72% and 69%, respectively. The modulus of elasticity also decreased by 71% at 90°, confirming anisotropy. Additional tests revealed a Brinell hardness of 179.9 N/mm ² , a water absorption of 19.75%, with minimal dimensional change, and a thermal conductivity of 0.1553 W/m·K. Microscopic analysis showed porosity and uneven fibre distribution, indicating the need for composite optimisation. These findings confirm the importance of orientation-aware design in large-scale additive manufacturing and provide the background for future work focusing on the development of printing strategies and computational modelling to enhance print quality, interlayer adhesion, and performance in applications.

This research is part of a comprehensive assessment of the feasibility and viability of large-scale additive manufacturing of load-bearing and non-load-bearing building structures made from sustainable biodegradable wood-based polymer composite. Mentioned material is made from polylactic acid (lignin) and softwood fibre – both waste products of the wood-processing industry, which have the property of total biodegradability in the environment. At the same time, composite have properties of durability, water resistance and elasticity of plastic, and mechanical behaviour and strength of wood. This study involved developing a design for a load-bearing building truss with computer modelling of its load-bearing capacity. For the calculation, the truss material – wood-based polymer composite – was characterised through tensile and bending tests according to ISO 527-4:2023 [10] and EN 310:1993 standards [11], from which a stress-strain diagram was derived and implemented in the Finite Element Model. The numerical simulation was performed in the SOFiSTiK environment using shell elements. Subsequently, topological optimisation of this truss was performed using the ANSYS Discovery software package, taking into account the actual loads on the truss elements, and the truss cross-sections were modified accordingly. Improvements to the truss design in ANSYS Discovery software resulted in a topologically optimised structure with a complex bionic shape (providing significant material savings, lower weight, but greater manufacturing complexity, and suitable for large-scale additive manufacturing). The results of this phase of the study demonstrate the effectiveness of using topology optimisation in ANSYS software for building structures. In the future, it is planned to produce a small-scale model of the developed truss using 3D printing from wood-based polymer composite and conduct laboratory testing of its load-bearing capacity for comparison with the data obtained as a result of computer analysis.