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ATLAS Upgrade WP4

Face to Face meeting

QMUL 9th May 2011

Richard French – The University of Sheffield

Ian Mercer – Lancaster, Martin Gibson, John Mattheson, Ian Wilmut RAL,

Georg Viehausser- Oxford

Cooling update task 2

Plans from Nov 2011 plus newNov 2011 RAL meeting

• Thermal shock work to be continued at RAL – Ian W re-jigged MG’s locker/coffin idea, RAL to produce drawings. Sheff, Lancs RAL fabrication. Can the QM box do the same job?

• Weld head mods at Sheffield – in talks with weld head manufacturer who can provide a basic, solid small head that we can retrofit anyone’s encoder to (supplier to known Austrian company)

• Bending to continue at Lancs – improved tooling and possible 3D CNC work – 3D done with manifold work. Waiting for direction. Sheffield producing tooling for small OD Ti.

• C02 cooling rigs x? On hold for now.• Services mock up at RAL supported by

Lancs and Sheffield – thick wall welding using RAL M100 = pretty successful.

• JM to continue blowing chips up – relay information to Peter Phillips to distribute to the community for acceptance. Excellent feedback from Upgrade week (Oxford). Looks very encouraging.

From Ox Upgrade week

• IBL Ti joint order proved very useful. Now looking to reduce wall further for production tube. Order ready, need to sort finance.

• FEI4 chip testing plus 130nm structures.

• Representative structure with BUS cable and cooling pipe is desirable. Look at fabrication in mid 2011 to tie in with the chip delivery.

• Broken welder, damaged weld head, another damaged weld head (detailed later in presentation)

• Ti VCR fittings – need to source stock from tube supplier as Smiths metals Ti won’t weld as well

• In-situ tube cutting and preparation.• Still 100% test success record.

Check VCR faces.

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Weld system failures• Just when you start to depend on something…… M200 weld system fails week

before AUW Oxford. Just mildly annoying and a waste of a week + weekend to be polite!

• 3 separate faults – has been working for 9 months with 2 of the faults undetected but obviously present on reflection as misfires and positional loss occurring more frequently.

• 5H (big) weld head heat damage, cracked encoder causing erratic rotational control when hot then total fall over of CPU in M200.

• M200 flash memory failure (same as normal PC) is suspected cause of power supply spike in MOSFET causing final encoder failure and loss of essential EXE files for operation.• SOLUTION = change memory pair and adopt regular service (£420+vat PA) • Cool tubes (Ag) internally even when simple non-essential welding to prevent

excessive heat build up in weld head(s).

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Sheffield micro-weld head

• 4H weld head failure – Cu electrode drive buckles during tack welds when used

with M100 power supply. Significant damage evident on head before loan ie our use - so a mater of time.

• 4H head does not cool well anyway. Swagelok do offer heat plates but our mod is better. Tack welding thick wall tube puts high heat spots on only metallic part adjacent to arc and it amazingly goes all bendy and jams gearing of drive mechanism. In turn the encoder and machine then get a little confused

RESOLUTION – Tack welding produces very high heat load on the weld heads & power supply (Capacitor charge/discharge and MOSFET control not fantastic on the Swagelok set up). Argon gas must be delivered internally and a reasonable delay put in the weld programme between tack welds to allow for cooling.

Titanium developmentsFull UK tube sock list available at this link to the TWIKI

• CP2 Ti purchased for both Stave and IBL using the same UK based company.

• 3 different diameters, 2 differing specs from our process refinement.

• 2009 1/8”x0.18 OD CP2, 10 week delivery from date of order

• 2010/11 joint order for evaluation and prototyping UK, US, NIKHEF, CPPM (22 weeks from thought –order-receipt)

• CP2 Ti 3.175x0.20x2200mm • CP2 Ti 2.275x0.15x3000mm • CP2 Ti 1.20x0.20x3000mm • 2011 production order UK/CPPM• CP2 Ti .275x0.10x3000mm

(90 Lengths = 135 Metres£ 49.25) Ordering Weds 11th May

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• Minimum of 10 week delivery time

• Problems we had should be fixed:• Ordering – SSC cost us a

minimum of 6 working weeks. In reality this was 3 months.

• Now more or less working? Flying pigs? Cat herding?

• Ian put all this through SSC last time. I can do this side now but I will need assistance with the refinancing back to STFC from CPPM at some point later on.

• Need to check if past invoices sent out to CPPM, NIKHEF &Brookhaven

Oxide reduction• 2010 Martin Wilson & Zhi-Jun Xin worked out

how to remove the Oxide with “nasty chemistry”. Problem is not a “scaled up” operation.

• Refined the Ti pickle with tube manufacture and a midlands chemical company.

• 2.275mm tube better but CERN report – trace of chlorine from water cleaning of pickle so instigating corrosion monitoring tests at Sheff.

• Refining further with tube manufacturer plus Swantek (Jerry Lancaster) for chlorine residue removal (NOT WATER) on the new 2.275x0.10mm

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Stave 09 Ti 2009-2010

IBL + StaveLet 130 Ti 2011

Pickling process attacks Ti as opposed to the oxide.CERN tests very good so will try on welded samples

Edge defect present on both internal & external surfaces. This is not a problem (yet) and may assist us.

Next few months view• 1.6 &1.2m long objects

• Pressure drop measurements Alexander Bildatze (GLA/CERN) testing all materials & diameters when built as circuits (no fittings). On target for end June delivery date to CERN from Sheffield. Sheffield now producing bend tooling for Lancs in “odd” sizes, internal formers made, external on machine. May 19th shipping to Lancs for 2.275mm Stave & Stavelet production + bending trails (minimum only to save material).

• Material reduction and procurement • New order for IBL-UK now ready to go (Weds 11th) this is as uncomfortable a wall size for

the welding (me) as possible. Grain size indicates very thin wall tube possible sub 80 micron. Oxidisation understood and pickle refined further

• Weld head development• Swagelok (Manc & US) actively discouraging 4H weld purchase. Looking at OEM for

assistance with body of head and retrofit parts. If this is not a “fast” option then will go with the 4H and use our existing modificaotins.

• Electrode type & profile• This has given the single biggest gain for the Ti welding. I’m now playing with electrode tip

angles and material (altering the Thoira content) to see if there is a better solution. Also need to purchase higher BIP grade Argon for greater improvements. Gas transfer line changed to 316L & PTFE = better for Ti.

• Fittings• Vac brazed stubs ready for manufacture (6LV VCR to Ti interface for welding)• Finding suitable, weldable material for Fred to make Ti fittings from is not at all easy, need

to source from Sandvik in HUGE quantities.

• Thermal shock etc in the pipe line at some point.

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