RHIC DX dipole magnet construction

The Relativistic Heavy Ion Collider DX dipole magnet has a bore of 180 mm, an overall length of 4.0 m, a nominal operating field of 4.28 T and a coil pre-load of 28 kpsi, A brief R&D program using short coil sections was used to verify the insulation scheme, to make sure the required coil pre-load c ould be achieved and to monitor the load loss over time. A full length prot otype magnet was built and tested, to verify the design, test out the tooli ng, fine tune the assembly procedures and measure the field quality and que nch performance. Changes were incorporated after each phase. This report de scribes each phase, including the problems encountered, the lessons learned , and the resulting changes made to the magnet design and assembly procedur es. Critical data from subsequent production magnets are also included.