Experience on Fabrication and Assembly of the First CLIC Two-Beam Module Prototype

The CLIC two-beam module prototypes are intended to prove the design of all technical systems under the different operation modes. Two validation programs are currently under way and they foresee the construction of four prototype modules for mechanical tests without beam and three prototype modules for tests with RF and beam. The program without beam will show the capability of the technical solutions proposed to fulfil the stringent requirements on radio-frequency, supporting, pre-alignment, stabilization, vacuum and cooling systems. The engineering design was performed with the use of CAD/CAE software. Dedicated mock-ups of RF structures, with all mechanical interfaces and chosen technical solutions, are used for the tests and therefore reliable results are expected. The components were fabricated by applying different technologies and methods for manufacturing and joining. The first full-size prototype module was assembled in 2012. This paper is focused on the production process including the comparison of several technical solutions adopted during the realization. The module assembly procedure and quality control measurements are also recalled.