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WP4 Report

WP4 Report. UK Annual Review RAL 10 th May 2011. WP4 Scope. WP4 Pedigree. WP4 essentially involves the development of:- low mass mechanical structures which define the position of modules in the tracker. Precision mechanical assembly tooling to manufacture staves

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WP4 Report

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  1. WP4 Report UK Annual Review RAL 10th May 2011

  2. WP4 Scope UK Annual Review (WP4)

  3. WP4 Pedigree • WP4 essentially involves the development of:- • low mass mechanical structures which define the position of modules in the tracker. • Precision mechanical assembly • tooling to manufacture staves • systems to mount modules • Test systems & procedures to validate stave performance • WP4 groups have delivered major components to various HEP experiments:- • Carbon-fibre structures • CDF (FNAL) Layer-00 support structure • LHCb (CERN) VeLo module base-boards • ATLAS (CERN) Design, procurement & assembly of CFRP support structures for SCT endcap • Precision mechanical assembly • SCT Module manufacture tooling • SCT Module mounting tooling • LHCb module assembly • QA for:- • Modules (ATLAS-SCT & LHCb-VeLo) • Structures (ATLAS-SCT, LHCb-VeLo, CDF-00) UK Annual Review (WP4)

  4. WP4 Monitoring • Face-to-face Meetings • Roughly every 6 weeks rotating around WP4 institutes • Agenda • Regular review of each task area • One-off topics • Provoke in-depth discussion /debate • Identify areas needing more work • Discuss work needed for • International commitments (eg international stave programme) • Cross-workpackage topics (eg irradiation) • Lab tours • Allows host institute to promote their work, facilities & staff engaged in the project • Weekly ‘Phone Meetings • 11 am to 12:30 every Monday via CERN telephone conference • Short reports from each Task Leader (or alternate) • Brief progress reports on specific items UK Annual Review (WP4)

  5. WP4 at Oxford • DESY (2010) 8/25 (32%) • CERN (2010) 8/19 (42%) • Oxford (2011) 18/42 (42%) UK Annual Review (WP4)

  6. WP4 Tasks & Context ATLAS Super-module Community International Stave Core Development WP4 Management • Materials Studies • (R. Bates) Forward Region Community International Stave Core Assembly • Integration • (I. Wilmut) • Cooling System • (R. French) Upgrade Steering Group Irradiations Management ID Layout Stave 09 Upgrade Project Office WP2 On Detector • Test/Shipping Container • (G. Beck) • Stave Core Assembly • (G. Viehhauser) ID Engineering WP3 Off Detector • Module Mounting • (I. Wilmut) ID Integration & Commissioning ATLAS Cooling Group UK Annual Review (WP4)

  7. Materials Studies • (R. Bates) Materials UK Annual Review (WP4)

  8. Materials Studies • (R. Bates) Moduli of Poco09 Z direction • Moduli measured with LVDT and Video Estensometer. • Video likely to be more accurate • Gives measurement of higher modulus • Measures bulk movement no jig movement • Insensitive to movements of the jig (or of foam edge) • FEAmodelling • Ligaments crush therefore measured strain is large • Results in low modulus • Model of foam reproduces measured values while also reproducing “real” bulk modulus correctly UK Annual Review (WP4)

  9. Sandwich Token Flatwise Tensile Testing • Materials Studies • (R. Bates) • Sandwich • Dimensions: 50 x 50mm • Facesheets: K13D2U 0/90/0 • Core: UCF-126-3/8-2.0 • Glue: Hysol 9396 UK Annual Review (WP4)

  10. CFRP Tensile Tests • Materials Studies • (R. Bates) • Mitsubishi K13D2U Fibre properties • Tensile strength 3690MPa • Tensile modulus 930GPa • Elongation at failure 0.4% • For 29%RC and 0/90/0 expect • Modulus = 930 x 0.71 x 2/3 • = 436 GPa UK Annual Review (WP4)

  11. Materials Studies • (R. Bates) Allcomp Foam Thermal Conductivity • Allcomp Foam is a lower density alternative to Pocofoam (ρ=0.55g/cc for the thermal interface between the cooling tube and the face sheet • First sample plate (30cm x 30cm x 3cm) purchased. • Measured 10 x 10 x 30 mm samples in all 3 directions close to RT • Appears reasonably isotropic, almost scales with density as desired • Previous discrepancy might be due to combination of sample preparation and measurement error • Plan is to use this foam in prototyping for low power (ABCN130) staves. ρ=0.22g/cm3: x= 34W/mK, y=38W/mK, z=34W/mK ρ=0.36g/cm3: x= 74W/mK, y=62W/mK, z=64W/mK UK Annual Review (WP4)

  12. Cooling System • (R. French) Cooling System UK Annual Review (WP4)

  13. Cooling System • (R. French) Orbital Welding powersupply weld head Butt weld centre line Heat Affected Zone (HAZ) is minimal with no tube distortion UK Annual Review (WP4)

  14. Cooling System • (R. French) Ti tube joining Titanium welding work is progressing: There are two main problem areas. • Electrode burn-out. • High arc temperature required for Ti welds is causing burn-out of Ciriated Tungsten electrodes. • Changed to Thoriated electrodes that we make in house with the correct length and tip. These tungsten electrode contains 2% Thoria which is slightly radioactive. • The new electrodes and allow for a cooler arc during welding. This improved weld quality without depositing tungsten into the weld. Lower power could be used and HAZ reduced. • Tube oxidisation. • CP2 Ti from UK supplier improved overnight based on little R&D. Working with them to refine the reduction of oxide further. • Oxide slowed the progress of the 1/8” or 3.175mm OD Ti welds – when the weld pool cools the sulphur and carbon from the Ti dioxide cause small porosity on the surface (cost about 8 man months) • Recent delivery of 2.2mm OD tubes have much less surface oxide and fewer contaminants - likely to result in smooth progress towards the manufacture of full cooling loops for stave(let) prototyping CP2 Ti (b) UK Annual Review (WP4)

  15. Cooling System • (R. French) Orbital Welding and FE damage FE ASIC ac-coupled detector arc Issue is whether the FE amplifier input is likely to be damaged by welding on nearby tube. Arc – tube – stave structure – bus tape – sensor – wirebond - FE One ABCN-25 channel has undergone a number of welds in proximity, no effect. Also with channel connected to pipe (results on next slide !) Need to repeat for ABCN-13 Possibility of using FE-I4 pixel FE (also 130nm technology) bus cable UK Annual Review (WP4)

  16. Cooling System • (R. French) ABCN-25 after welding, test electrode bonded to input – capacitance causes excess noise ABCN-25 after welding, bond pulled from input – gain, noise of tested channel normal UK Annual Review (WP4)

  17. Stave Core Assembly • (G. Viehhauser) Stave Core Assembly UK Annual Review (WP4)

  18. Stave Core Assembly • (G. Viehhauser) Stave Assembly Issues • Specifications • WP4 now engaged in activities to help to define the thermo-mechanical specifications for staves • Fully engaged with new ATLAS Upgrade management structures • Thermal design for low(er) power ABCN130 • Understand requirements wrt support structures • Mass Reduction • Glue layers are ‘dead material’ and can be hard to control. Reduce mass by: • Eliminating adhesive between bus tape and face sheet (i.e. try to develop co-curing) • Eliminate / reduce adhesive between face sheet and core (i.e. minimisation of glue volume, use co-curing to attach core to face sheets – NGLS) • Global Optimisation • Optimise distribution of material between support structure and staves to maximise performance (stability) and minimise material • Assembly Issues • Component costs (do we really need K13D2U, CF honeycomb…?) • Tooling (can we improve the flatness of staves ?) • Manufacture (can we reduce fabrication time?) • QA (can we prove that our staves are fit for purpose?) UK Annual Review (WP4)

  19. Stave Core Assembly • (G. Viehhauser) Co-curing – results • 7 electrical and 2 mechanical co-cures of full size tapes & 4 stavelet size • Issues • Co-cured face sheets can be sucked onto vacuum jig, although residual curvature difficult to control along edge. • In autoclave gluing edge of tape needs to be protected from glue creep with tape. • Residual twist in electrical tapes (thicker aluminium?) • Dimensional changes • Face sheet integrity • Inside / outside cure – which is better ? Autoclave cures for 0.5mm stavelet on CF Tooling Press cures for full length stave Autoclave cures for full length stave UK Annual Review (WP4)

  20. Stave Core Assembly • (G. Viehhauser) Corrugated Cores • Why ? • CF honeycomb cost • Issues with gluing HC • Control of glue volume • Adhesion • Mass • Manufacturing • Grinding > 0.6m requires multiple re-positioning of jig on machine Stave Cost Fractions • Plank #5 – corrugated core • corrugation with dot pattern • BN loaded glue for POCOfoam as usual (applied onskin, masked and scraped flat to flash-breaker tape thickness) • Glue for side closeouts (C-channels) applied on closeout • Leaked out during top skin gluing → bonded stave to jig, delaminated top layer of tape (not tape from CF, or CF, or CF from closeout) in one location, repaired. • Leakage problem observed in the past, in the future cut tapes to size only after gluing into staves, just wanted to use up old tapes. UK Annual Review (WP4)

  21. Stave Core Assembly • (G. Viehhauser) Step 2 Step 1 Nearly GluelessStavelet Attempt to reduce glue mass (~ 10% for conventional build) by using resin in pre-preg to attach face sheet to core components. UK Annual Review (WP4)

  22. Stave Core Assembly • (G. Viehhauser) Glue-film Investigations (Stavelet #6) • ACG VTA260 film 188gsm • Use CNC pattern cuter to remove mass (60% removed) • Use film & backing as a template for BN loaded Hysol • Potential drawback is 65-80C cure – alternative films ? • Successfully used on Stavelet #6. Current design has 2.2mm wide glue lines – plan to investigate thinner lines (1.5, 1mm?) UK Annual Review (WP4)

  23. Stave Core Assembly • (G. Viehhauser) Current Developments – Tooling • Programme to develop low(er) mass, more stable stave assembly tooling • Start with CF sandwich version of stavelet tooling to prove manufacturing techniques • 1.5mm CF skins on 7mm Nomex honeycomb • Embedded vacuum channel • FR4 vacuum channel network • ~ 380 2mm dia. vacuum holes • Extend to full stave tooling by Autumn Stavelet jig: Surface flatness +0.03mm UK Annual Review (WP4)

  24. Stave Core Assembly • (G. Viehhauser) Thermo Mechanical Stave Tests TM stave mounted in box using stave locking mechanisms. Power supply and hybrid temperature monitoring system connected via EOS board, temp results taken by LabView Hybrid strips Stave locking mechanisms 0W 83 158 Silicon 24 UK Annual Review (WP4)

  25. Thermo-mechanical Results Thermal impedance (dT/dQ) uniformity • Stave Core Assembly • (G. Viehhauser) • FEA of one quarter module • For 1W ASIC heat per module face (40 ASICs). • Fluid-wall HTC assumed 8000 W/m2K. • Conduction only. • Thermistor temperature rise (above fluid): 1.03 °C/W (module) = 0.043 °C/W (total) Temp U2 Temp U3 Temp U1 1/40W into each asic Sensor D1 (Z) Sensor D2 Sensor D3 Sensor D4 Sensor D5 0.1C contours Thermal resistance (hybridΔT/total power): Top: 0.0425 ± 0.0024 °C/W Bottom: 0.0474 ± 0.0030 °C/W All: 0.0449 ± 0.0037 °C/W -30°C fluid Resultant thermistor temperature: -28.97°C Temp T1 Temp T3 Temp T2 UK Annual Review (WP4)

  26. Stave Core Assembly • (G. Viehhauser) Preparations for ESPI Studies • Allows measurement of mechanical deformations. • Sensitive to ~300nm out-of-plane. • ~900nm in-plane. • Full-sized stave housed in environmental chamber. • Chamber has cooling, also have direct liquid cooling of stave. CO2 cooling imminent. • Aspherical optics used to illuminate whole stave at once. • For proper understanding of behaviour need proper mounting arrangement. Stave held by springs at ends – no intermediate supports approx ΔT = 0.16°C UK Annual Review (WP4)

  27. Stave Core Assembly • (G. Viehhauser) Staveletthermal imaging Transverse T profile: -25°C • Cooled with CO2 at pevap~13bara. • Thermal load from environment (at about 20°C, heat load 60-80W). • Imaging CF skin covered with masking tape. • Transverse temperature variations match simple FEA. -32°C -25°C UK Annual Review (WP4)

  28. Stave Core Assembly • (G. Viehhauser) Edge-mounted locking mechanics • Proper locking of stave along one edge • Flexible number of intermediate locking points (now: 5) to be engaged from barrel end. • Single reference point to anchor local (stave) coordinate system to global (cylinder) system (at z=0). • Compatible with stave end-insertion • Optimize material by support along one edge only. • One set of locking parts machined and attached to Thermo-mechanical Stave Locking force Reference surfaces UK Annual Review (WP4)

  29. Stave Core Assembly • (G. Viehhauser) Longitudinal Load -- displacement curve (locked) Initial stiction Friction due to finger springiness Finger disengaged (not pressingon Bracket core) Load -- displacement curve when locked finger disengaged (not pressing on Bracket barrel) Stave-to-Cylinder Interface • For full structure FEA need to understand response of locking points • What’s the friction for z-movement? • What effect do the contact points have? • Do staves do play role in stiffening the support cylinder ? Fully locked Fully sliding Fully bonded UK Annual Review (WP4)

  30. Module Mounting • (I. Wilmut) Module Mounting UK Annual Review (WP4)

  31. Module Mounting • (I. Wilmut) Items Constructed Fabricated a full sized (1.2m) double sided thermo-mechanical stave Fabricated a short (0.5m) single sided electrical stavelet UK Annual Review (WP4)

  32. Module Mounting • (I. Wilmut) Future..... Designing a full size stave assembly system that will cope with a ‘1.6m’ stave (if needed) and could be extended to allow module mounting for 2 sides per day. • Storage for 1.6 metre staves on order. • Optics up and running (development of system previously used in construction of SCT modules). • XYZ Stage system on order. Delivery July 2011. • Infrastructure (vacuum system, fume extraction , safety interlocks, etc) being designed and constructed. Clean room space at RAL allocated UK Annual Review (WP4)

  33. Test/Shipping Container • (G. Beck) Stave Test / Shipping System UK Annual Review (WP4)

  34. Test/Shipping Container • (G. Beck) ASSEMBLED STAVELET INSTALLATION / SHIPPING FRAME Stavelet Shipping Frame PROFILE MACHINED TO MATCH LOCKING MECHANISM MOUNTING BLOCKS Stavelet Shipping Frame Located in module mounting frame FIDUCIAL MOUNTING HOLES UK Annual Review (WP4)

  35. Test/Shipping Container • (G. Beck) Stave Thermal Cycling • 2m long chamber • Electrical heater • LN2 cooling • Cycle time ~ 1hour UK Annual Review (WP4)

  36. Test/Shipping Container • (G. Beck) Plank #4 (low density foam) Delamination areas Plank 4 (poor quality foam core) • Stave Thermal Cycling • Overall plan is to carry out 50 cycles. • Visually inspect after every 10 cycles • No sign of delamination after 10 cycles • C channel delamination in evidence after 20 cycles • All the de-lamination appears to take place between the C channel and the face sheet • Longer term also monitor humidity • Required to achieve a Dew Point of -60C RH of 1%@ -20 C • Ongoing • Still need to improve lid seal. • Runs per 120ltr dewar = slight improvement (12 runs) UK Annual Review (WP4)

  37. Test/Shipping Container • (G. Beck) Plank #5 - Ripples & De-laminations • Ripples in Plank 5 tapes seen after few 10’s of thermal cycles • Issue with tape manufacture • De-laminations (within CF facesheet) in 125C co-cured K13D2U/RS3 facesheets (US tapes) after 1 hour at -45C • Pre-preg selection • Latest batch is K13C2U/EX-1515 • Lower cure (135C) • More resin 32% vs 29% • First trials imminent • UK supplier approached & is interested in delivering 80C cure pre-preg • Focus turning to theoretical calculations / FEA modelling of stresses in co-cured structures together with a prototyping plan for verification Tape Sandwich UK Annual Review (WP4)

  38. Integration • (I. Wilmut) Integration UK Annual Review (WP4)

  39. Integration • (I. Wilmut) Building on previous work and following a number of layout iterations the UK have concentrated on a 1/32nd modularity (Service Module) UK arrangement of patch panel and services routing updated March 2011. This has looked at ideas for incorporating End Cap and pixel services that could be modelled in the full size mock-up (based at RAL) Integration - UK Mock Up development The latest UK 3D services layout shows repeatability of stave cooling pipes for a service module occurs after eight instances

  40. Full size Mock Up and layouts • Integration • (I. Wilmut) • Initial thoughts behind the ID mock up • Full size mock up begins to give us a ‘feel’ for what challenges lie ahead • Half section preferred. A lab made available for this at RAL and mechanically it will be easier to construct than a quadrant. • Initial studies focused on barrel cooling arrangement and trials on pipe welding. • Latest Service Module layout • Pipes mimic current layout, formed from available 1/8” St/steel tubing. • Dark/sleeved area indicates region of proposed weld. • Current layout includes extra straight sections to allow for re-welds of link pipes connecting stave to main service module pipes UK Annual Review (WP4)

  41. Integration • (I. Wilmut) Welding Trials on UK Mock Up Photos show first trial welds (Swagelok orbital 5H head system ) Orbital Welding System Swagelok M200. Trials and development of its use with stainless steel piping has been undertaken at Sheffield University. Swagelok 4H orbital weld head is smaller in size which naturally has advantages within a complex pipe layout UK Annual Review (WP4)

  42. WP4 Deliverable Summary UK Annual Review (WP4)

  43. WP4 Full Milestone List UK Annual Review (WP4)

  44. WP4 Accomplishments & Issues UK Annual Review (WP4)

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