Fabrication of First 4-m Coils for the LARP MQXFA Quadrupole and Assembly in Mirror Structure

The US LHC Accelerator Research Program is constructing prototype interaction region quadrupoles as part of the US in-kind contribution to the Hi-Lumi LHC project. The low-beta MQXFA Q1/Q3 coils have a 4-m length and a 150 mm bore. The design is first validated on short, one meter models (MQXFS) developed as part of the longstanding Nb$_{3}$Sn quadrupole R&D; by LARP in collaboration with CERN. In parallel, facilities and tooling are being developed and refined at BNL, LBNL, and FNAL to enable long coil production, assembly, and cold testing. Long length scale-up is based on the experience from the LARP 90 mm aperture (TQ-LQ) and 120 mm aperture (HQ and Long HQ) programs. A 4-m long MQXF practice coil was fabricated, water jet cut and analyzed to verify procedures, parts, and tooling. In parallel, the first complete prototype coil (QXFP01a) was fabricated and assembled in a long magnetic mirror, MQXFPM1, to provide early feedback on coil design and fabrication following the successful experience of previous LARP mirror tests.