CLRC 1D. Greenfield

UK-VEnd-cap Engineering

15 July 2003

Debbie Greenfield, RAL

CLRC 2D. Greenfield

SCT End-cap Support Structures

- Cylinder and Supports Engineering Program (pre-manufacture)

» Series of mechanical tests on laminates,sandwich panels and material qualification tests (eg. Fibre volume content)

– All very good except problems with flatwise tensile strength in front and rear support sandwich panels

– Will change from Ultem inserts to CF– Contractual negotiations underway

» Mechanical tests on inserts - all exceeded requirements» CME and CTE - still awaiting some CME but all CTE and

CME results so far exceed requirements Production

» Support Structure 1 was due for delivery July 2003– Bare Support Cylinder manufactured – Will be a delay in the Front and Rear Supports

CLRC 3D. Greenfield

Complete Support Cylinder

CLRC 4D. Greenfield

Produced CC/PEEK sandwich at RAL

Extensive testing of CC material inc. x-ray and thermal conductivity measurements at 3 institutes

Conclusion is that all the CC material is fine

Assembled blocks to middle and outer circuit and assembled middle circuit to CheapO

Placed initial order - enough for 2 disc 8s, 2 disc 9s and 1/4 DiscO.

End-Cap Cooling Structures Main and Second Cooling Block

Production

CLRC 5D. Greenfield

Order placed with industrial company for a pre-series of main wiggly sections for outers and middles.

Pipe from US turned out not to have been annealed

Trial anneal now done by Bodycote Awaiting grain analysis results

before annealing remainder Second point and joining pieces

made at RAL with no filler Custom made pipe bender

manufactured Assembled in soldering jig at RAL

End-Cap Disc ServicesCooling Circuit Production

CLRC 6D. Greenfield

Prototype Disc Assemblybased on CheapO disc

All available pre-production services being assembled onto CheapO. Includes:» Complete middle and outer cooling circuits» Wiggly tapes» Opto harnesses» Grounding foils » Dummy hybrids

Still working on back – then need to do front Very useful – need another couple of weeks Still to do:

» Thermal movement test» Delta P test (needs dummy thermal modules)» FSI component placement (needs modules)

CLRC 7D. Greenfield

CLRC 8D. Greenfield

Services from PPF0 to PPF1

Design work has progressed well for the PPF1 electrical and cooling patch panels.

Prototypes have been installed on the mock-up at CERN. Much work done to work out the LM tape lengths. Design of cooling along the cylinder is on hold until the heat

exchanger and capillaries are defined. This will soon be critical.

CLRC 9D. Greenfield

SCT End-cap Support Structures

- Discs 4 bare discs produced in spec. and received at NIKHEF All discs should be received by end Dec 2003 Last 2 discs failed the Flatwise Tensile Test at PCI

» YLA have tested the materials but not found contamination» PCI are now checking their procedures and processes» No new delivery date yet» This problem does not impact the disc-with-services

schedule yet as 4 good discs are at NIKHEF

CLRC 10D. Greenfield

SCT End-cap Support Structures

- Discs Disc 8A and 8C have had their apertures machined.

» Start bonding inserts on Wed. Discs 9C and 9A are being prepared for aperture machining.

» 9C will be started on Tue. 9A will follow soon after. Then will start remachining the stiff base-plate on Mon 21 July.

» More precision spheres (8 instead of 3)» 16 adjustable supporting pins on the outer and 8 on the

inner edge» expected to finish tooling Aug 8th» Then machine DiscO (2-3 weeks)» Then machine 9C

Expect to deliver disc 9C to RAL in the middle of Sept.

CLRC 11D. Greenfield

Disc Schedule First disc arrives at RAL mid-September 4-5 weeks for services addition Discs to Liverpool:

» Disc 9 - mid October» Disc 8 - mid November» Disc 7 – beg January 2004

CLRC 12D. Greenfield

Services Schedule Tim Jones recently appointed as Services Coordinator

The objective is to do everything possible to ensure that Disk-9 gets to Liverpool by mid September as required for assembly.

Establish a list of all of the parts needed to produce (the first) discs to the point that they are available for module assembly.

Establish an agreed week by week schedule Follow the progress of all parts and update me on a weekly basis Where problems are encountered, help find solutions Ensure that shipping arrangements are in place

All services should be ready for first disc but very tight