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Cooled Carbon Support Development: Recommendations for Lightweight Applications

This document provides recommendations for developing cooled carbon structures for lightweight applications, focusing on increasing thermal conductance, toughness, and leak-tightness of tube manifolds. It discusses concepts such as the "fintubing" and "tubewall" options and suggests using POCO graphite materials for improved performance. Prototypes and superstructure options are also explored to enhance structural integrity and heat exchanger performance.

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Cooled Carbon Support Development: Recommendations for Lightweight Applications

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  1. Cooled Carbon Support BTeV Pixel Detectors Development Recommendations for 2001 T R Knowles 3/7/01

  2. FY00 Progress • Cooled carbon structure demo articles (full-scale) • Lightweight • Rigid • Shingled surface • Porous chip mount • Al manifolds • Issues • Resistance at tube wall is high • Need to increase thermal conductance • Tubing cracked, leaked • Need to increase toughness and assure leak-tightness Fibrous surface for shingling with high contact conductance Vertical high-k fibers with in-plane discrete fiber reinforcements Tubes cemented in grooves

  3. Increase Thermal Conductance • “Fintubing” Concept • Improved fiber orientation • Issues: Precision? Manifolds? • “Tubewall” Concept • Complete layer of tubing • Tubing height < 1 mm • Issues: Precision, Rigidity? Manifolds

  4. POCO graphite rod CVD POCO tube, (unreinforced – 8 ksi) Graphite Header Tubing • Sealed POCO graphite tube • Tube machined from POCO • Pyrocarbon CVD seal coat • Helium leak test • Light CVD seal reduced He permeation to <5e-9 mL/s (most sensitive scale on leak detector) • Expect heavier coat to seal even better (no helium leak signal) • Good candidate for headers • May reinforce with carbon braid to improve strength and toughness

  5. Tube Manifolding • Carbon carbon construction • Tubular elements • Large-gauge headers • Small-gauge lines • Carbon joining • Carbonize bonding resin • Seal by pyrocarbon CVD • Reinforcement options • Integral boss on graphite header for larger tube/header interface • Fabric reinforcements

  6. FY01 Task 1Review Issues and Options • THERMAL “fintube” and “tubewall” options • Fabricate small comparison articles • STRUCTURAL fibercore; carbon fiber frame • Fabricate small comparison articles • MANIFOLDING aluminum vs carbon • Fabricate carbon-carbon T-joint to test hermiticity • TOUGHNESS reliable tube/manifold connection • Fabricate stress-relieved joints with velvet or fabric

  7. FY01 Task 2Fabricate Prototypes • Fabricate two (2) Cooled-Carbon Supports • Incorporate design features selected from Task 1 • Assure leak-tightness by monitoring throughout fabrication • Mount on aluminum frames; attach inlet and outlet lines • Preliminary heat exchanger performance test at ESLI • Measure flow impedance • Measure heat exchanger performance • Theater - Tcoolant when symmetrically heated @ 1 W/cm2

  8. FY01 Task 3Superstructure Options • Work together with FNAL engineering to draft design of support superstructure based on • Lightweight sandwich structures • Carbon tubing • Carbon truss superstructures bulkheads carbon rod space frame

  9. Carbon Truss Structure Concept • Carbon sheet (100 µm) bulkheads • Carbon-fiber rods in tension • Carbon tubing & manifolds • Carbon fibercore thermal area

  10. Cost/Schedule

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