Assembly techniques used in construction of neutrino horns at BNL

This paper describes the techniques used in the assembly of the neutrino focusing horns which were installed in the fast extracted beam at the Alternating Gradient Synchrotron. The horns are coaxial magnetic lenses that are pulsed to a maximum of 14 kV and 300 kA. The materials and techniques used are further complicated by the fact that the horn must survive in a high radiation environment. The authors describe both the techniques and materials that were used in making the high current electrical connections. This includes the silver plating of aluminum, methods for handling thermal expansion and large magnetic forces, and the fabrication of rigid coaxial conductors. The techniques described in this paper can be used in the assembly of any pulsed high current device