Quality Control Techniques Applied to the Large Scale Production of Superconducting Dipole Magnets for LHC

The LHC accelerator, under construction at CERN, is characterized by the use on a large scale of high field superconducting dipoles: the 27-km ring requires 1232 15-m long dipole magnets designed for a peak field of 9 T. The coils are wound with Rutherford-type cable based on copper-stabilized Nb-Ti superconductors and will be operated at 1.9 K in pressurized superfluid helium. The challenge that had to be faced has been an efficient, cost-effective and reproducible mass production to very tight tolerances: the field quality must be better than 10-4 and the geometry of the cold bore tube and magnet controlled to 0.1 mm over the whole length, any deviation being liable to induce delays and significant cost increase. This paper presents the main methods and tools chosen to face successfully this challenge: some methods were foreseen in the technical specification, others were implemented based on the experience gained in several years of fabrication.