Lawrence Berkeley National Laboratory

Electron Cyclotron Resonance Ion Sources (ECRISs) that utilize Nb-Ti superconducting coils for 28 GHz frequencies have been operating effectively for over twenty years. However, transitioning to higher frequencies demands stronger magnetic fields, and the conventional racetrack-and-solenoid ECRIS structures have reached their maximum capability with Nb-Ti. To address this, a Mixed Axial and Radial field System Demonstrator (MARS-D) is being developed at Lawrence Berkeley National Laboratory (LBNL). This system features an innovative Closed-Loop Coil (CLC) design that optimizes the use of the conductor fields, enabling the application of Nb-Ti in the next-generation 45 GHz ECRISs. The fabrication of the hexagonal CLC is particularly challenging due to its complex winding path and shape, the stiffness of the Nb-Ti superconducting wire, and the small bending radius. To address these challenges, a series of unique fixtures and tools, as well as a pre-over-bending method, were developed for winding the CLC. To validate the winding fixtures, tools, procedures, and materials used in the coil assembly, a 4-layer practice CLC was wound, epoxy-impregnated, and then cold-tested using liquid nitrogen. The full-size MARS-D CLC is in the process of winding. This paper presents the structure of the MARS-D CLC, the winding fixtures and tools, the winding procedures, the quality control, the impregnation, the test results, and the potential future improvements.