{"id":2045,"date":"2025-11-05T16:00:13","date_gmt":"2025-11-05T15:00:13","guid":{"rendered":"https:\/\/www.saesgetters.com\/highvacuum\/?p=2045"},"modified":"2025-11-18T15:47:25","modified_gmt":"2025-11-18T14:47:25","slug":"engineering-excellence-for-lbnl-als-u-saes-rial-vacuum-dipole-chambers","status":"publish","type":"post","link":"https:\/\/www.saesgetters.com\/highvacuum\/engineering-excellence-for-lbnl-als-u-saes-rial-vacuum-dipole-chambers\/","title":{"rendered":"Engineering Excellence for LBNL ALS-U: Dipole Chambers manufacturing"},"content":{"rendered":"<div class=\"container\">\n      <div class=\"col-6\">\n      <div>\n        <h2 class=\"h3 title\">At SAES RIAL VACUUM, precision meets innovation.<\/h2><p data-start=\"563\" data-end=\"839\">SAES RIAL VACUUM&#8217;s contribution to the <a href=\"https:\/\/als.lbl.gov\/als-u\/overview\/\"><strong data-start=\"661\" data-end=\"726\">ALS-U project at Lawrence Berkeley National Laboratory (LBNL)<\/strong><\/a> represents the successful accomplishment of a challenging project.<\/p>\n<p data-start=\"841\" data-end=\"1098\">Each dipole chamber for the <strong data-start=\"869\" data-end=\"910\">Advanced Light Source Upgrade (ALS-U) <\/strong>&#8211; a project designed to push the boundaries of synchrotron research by delivering brighter, more coherent beams for the scientific community &#8211; required an novel approach to design integrity, surface quality, and dimensional precision.<\/p>\n<p data-start=\"1223\" data-end=\"1386\">Through collaboration, <strong data-start=\"1251\" data-end=\"1292\"><a href=\"https:\/\/saesrial.com\/\">SAES RIAL VACUUM<\/a> and SAES High Vacuum<\/strong> strengthen their role as trusted partners in enabling cutting-edge research around the world.<\/p>\n      <\/div>\n    <\/div>\n        <div class=\"col-6\">\n      <div>\n              <\/div>\n    <\/div>\n    <\/div>\n\n\n<div class=\"container\">\n    <div class=\"col-12\">\n    <h3 class=\"h3 title\">Watch the video to explore the main steps of the manufacturing process<\/h3><p><iframe loading=\"lazy\" title=\"SAES RIAL VACUUM - Dipole Chamber fabbrication for  LBNL ALS-U project\" width=\"1440\" height=\"810\" src=\"https:\/\/www.youtube.com\/embed\/z06XAXvfDmI?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe><\/p>\n  <\/div>\n<\/div>\n\n\n<div class=\"container greyed\">\n  <div class=\"col-12\">\n    <div class=\"accordion\">\n      <h3 class=\"h3 title\">01. Material procurement<\/h3><div class=\"content\"><p data-start=\"1158\" data-end=\"1523\">For the LBNL dipole chambers, <strong data-start=\"1239\" data-end=\"1280\">high-purity Cu alloys<\/strong> were procured to ensure excellent mechanical strength and minimal vacuum outgassing.<br data-start=\"1358\" data-end=\"1361\" \/>All materials underwent <strong data-start=\"1382\" data-end=\"1423\">chemical and mechanical certification<\/strong>, guaranteeing traceability and compliance with the demanding requirements of accelerator technology.<\/p>\n<\/div>    <\/div>\n  <\/div>\n<\/div>\n\n\n<div class=\"container greyed\">\n  <div class=\"col-12\">\n    <div class=\"accordion\">\n      <h3 class=\"h3 title\">02. Hydroforming<\/h3><div class=\"content\"><p data-start=\"1721\" data-end=\"2080\">The chambers were shaped through <strong data-start=\"1754\" data-end=\"1770\">hydroforming<\/strong>, a process that uses high-pressure fluid to form complex geometries from raw tubes.<br data-start=\"1859\" data-end=\"1862\" \/>This technique allows for a complex geometry, <strong data-start=\"1888\" data-end=\"1914\">uniform wall thickness<\/strong>, and a <strong data-start=\"1953\" data-end=\"1981\">superior surface finish<\/strong> \u2014 all critical parameters for maintaining UHV (Ultra-High Vacuum) conditions inside the chamber.<\/p>\n<p data-start=\"2082\" data-end=\"2247\">Achieving<strong> the exact curvature<\/strong> and dimensional tolerance along the entire tube length while <strong>avoiding micro-deformations<\/strong> that could compromise vacuum sealing was the main challenge.<\/p>\n<\/div>    <\/div>\n  <\/div>\n<\/div>\n\n\n<div class=\"container greyed\">\n  <div class=\"col-12\">\n    <div class=\"accordion\">\n      <h3 class=\"h3 title\">03. Electron Beam Welding (EBW)<\/h3><div class=\"content\"><p data-start=\"2297\" data-end=\"2546\">Once formed, the components were joined using <strong data-start=\"2343\" data-end=\"2368\">electron beam welding<\/strong>.<br data-start=\"2369\" data-end=\"2372\" \/>This process, performed in vacuum, allows for <strong data-start=\"2418\" data-end=\"2464\">deep, narrow, and contamination-free welds<\/strong>, essential for vacuum components\u00a0that require a precise and clean inner-surface finish with leak-tight welds.<\/p>\n<p data-start=\"2548\" data-end=\"2691\"><strong>Maintaining alignment<\/strong> of component parts and c<strong>ontrolling thermal distortion during welding<\/strong>, given the sub-millimeter dimensional precision required, was fundamental in this step.<\/p>\n<\/div>    <\/div>\n  <\/div>\n<\/div>\n\n\n<div class=\"container greyed\">\n  <div class=\"col-12\">\n    <div class=\"accordion\">\n      <h3 class=\"h3 title\">04. Dimensional inspection with ZEISS technology<\/h3><div class=\"content\"><p data-start=\"2759\" data-end=\"3031\">After welding, each chamber underwent <strong data-start=\"2797\" data-end=\"2827\">3D metrological inspection<\/strong> using <strong data-start=\"2834\" data-end=\"2879\">ZEISS coordinate measuring machines (CMM)<\/strong>.<br data-start=\"2880\" data-end=\"2883\" \/>This step ensured that every geometric parameter \u2014 from curvature to flange alignment \u2014 matched the strict design specifications required for ALS-U.<\/p>\n<\/div>    <\/div>\n  <\/div>\n<\/div>\n\n\n<div class=\"container greyed\">\n  <div class=\"col-12\">\n    <div class=\"accordion\">\n      <h3 class=\"h3 title\">05. Ultrasonic cleaning<\/h3><div class=\"content\"><p data-start=\"3220\" data-end=\"3508\">Cleanliness is fundamental to vacuum performance.<\/p>\n<p data-start=\"3220\" data-end=\"3508\">Each chamber was <strong data-start=\"3287\" data-end=\"3313\">ultrasonically cleaned<\/strong> in a multi-stage process using controlled etchants, deionized water and alcaline detergents.<br data-start=\"3384\" data-end=\"3387\" \/>This procedure removes all particulate matter and hydrocarbon residues, and most importantly prepares internal surfaces for the final coating.<\/p>\n<\/div>    <\/div>\n  <\/div>\n<\/div>\n\n\n<div class=\"container greyed\">\n  <div class=\"col-12\">\n    <div class=\"accordion\">\n      <h3 class=\"h3 title\">06. NEG Coating (Non Evaporable Getter)<\/h3><div class=\"content\"><p data-start=\"3700\" data-end=\"3977\"><a href=\"https:\/\/www.saesgetters.com\/highvacuum\/solution\/neg-coating\/\">NEG Coating<\/a> is the final step of the manufacturing process of the ALS-U Dipole Chambers.<\/p>\n<p data-start=\"3700\" data-end=\"3977\">It consists of the deposition of a thin film of a Non Evaporable Getter material that, once activated, continuously absorbs residual gases inside the vacuum chamber,\u00a0 dramatically reducing at the same time PSD (Photon Stimulated Desorption) and ESD (Electron Stimulated Desorption).<br data-start=\"3859\" data-end=\"3862\" \/>This technology, mastered by <strong data-start=\"3892\" data-end=\"3900\">SAES High Vacuum<\/strong> for more than 20 years, significantly improves long-term vacuum stability and beam reliability, and is an enabling technology for multibend achromat synchrotron light sources.<\/p>\n<\/div>    <\/div>\n  <\/div>\n<\/div>\n\n\n<div class=\"container\">\n      <div class=\"col-6\">\n      <div>\n        <h2 class=\"h3 title\">Discover more about our solutions for particle accelerators and research facilities<\/h2>              <a class=\"btn\" href=\"https:\/\/www.saesgetters.com\/highvacuum\/applications\/particle-accelerator\/\">\n                <span class='the-arrow -left'>\n                  <span class='shaft'><\/span>\n                <\/span>\n                <span class=\"main\">\n                  <span class=\"text\">Discover more<\/span>\n                  <span class='the-arrow -right'>\n                    <span class='shaft'><\/span>\n                  <\/span>\n                <\/span>\n                <span class=\"circle-effect\"><\/span>\n              <\/a>\n                    <\/div>\n    <\/div>\n        <div class=\"col-6\">\n      <div>\n              <\/div>\n    <\/div>\n    <\/div>\n\n\n<div class=\"space space-l\">\n<\/div>\n","protected":false},"excerpt":{"rendered":"","protected":false},"author":7,"featured_media":2046,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"inline_featured_image":false},"categories":[1],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v21.7 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Engineering Excellence for LBNL ALS-U: Dipole Chambers manufacturing | SAES High Vacuum<\/title>\n<meta name=\"description\" content=\"Discover how SAES RIAL VACUUM supported the LBNL ALS-U project with the manufacturing of precision-engineered dipole chambers for the storage ring.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.saesgetters.com\/highvacuum\/engineering-excellence-for-lbnl-als-u-saes-rial-vacuum-dipole-chambers\/\" \/>\n<meta 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