Winding Challenges and Solutions in the INFN Falcon Dipole Project

The Falcon Dipole is a project led by the Italian Institute of Nuclear Physics (INFN), which aims to fabricate a 12 T short model of a Nb 3 Sn cos-theta accelerator dipole as part of the High Field Magnet (HFM) R&D program at CERN [1]. The status of the project is at the fabrication step of the first dummy coil in the industry and, in this paper, the results of the first campaign of winding tests conducted in the industry are presented. The winding process for the Falcon Dipole is challenging because the size of the Rutherford Cable used for the coils is comparable to the bore radius. This results in high bending and torsion stresses, making the cable structure unstable. To address these challenges, the previous 3D model has been modified to improve the winding feasibility. The setup has been prepared to monitor technical parameters that will help in modeling the coil geometry and identifying sources of critical issues. In this paper, the outcomes of the winding campaign are reported and the proposed changes to the coil end design to address the issues that arose are discussed.