Thermo-mechanical petal status

Sergio Díez Cornell

23Jan 2015

2

Petal thermo-mechanical “project”

“Deliverables” at the end of 2016: 14 petal cores of several flavors, 2 of them thermo-mechanical and the rest for module mounting

23 Jan 2014

Components/actions Nov 2014 Dec 2014 Jan 2015 Feb 2015 Mar 2015

Bus tapes

Facings

Honeycomb(s)

Pipes

Allcomp foam

E breaks ?

Closeouts

Locking points

Core gluing

Core milling

Dummy sensors

Hybrids

ASICs

DC-DC dummies

EoP dummies

Manufacture at Elgoline

Co-curing (Liverpool)

Cut and glue trials Cut to size

Cut and glue trialsReceiving Cut to size

Test

Bending and test

Manufacture in PEEK Manufacture in CF (Liverpool?)

Final design Manufacture in PEEK

Gluing step 1 Gluing step 2

Milling step

Design, manufacture, cut to size (IMB-CNM Barcelona)

Design, manufacture (Freiburg) Assembly of dummies (Zeuthen, Freiburg, IFIC)

Assembly of dummies (Zeuthen?)

Assembly of dummies (Zeuthen?)

Design and manufacture of jigs

Assembly of dummies (Zeuthen, Freiburg, IFIC)

Start loading first cores with dummies here

Assembly of dummies (Zeuthen, Freiburg, IFIC)

3

Facings and bus tapes

Bus tapes at Liverpool, ready for co-curing T. Jones merged .dxf files of bus tape with CAD files for facesheets:

• Found a 1.4 mm misalignment of locking point pin, which he was planning to use for alignment:

• Need to double check this again! • Still go ahead for this round of petals? Edges of bus tape (>2 mm of Kapton will still make up

for the misalignment. Cutting tool (at DESY) will get overall shape correct• Not so much worried about bonding pads, only interested in the power lines for these

prototypes

23 Jan 2014

4

Honeycomb

Both CF and N636 honeycombs in hand at DESY First petal in CF Second petal in N636

• Issues with N636 grinding due to epoxy content, also observed in the past by Liverpool• Several companies even refused to do it!

Both the CF and N636 will be milled in-house at DESY (same approach as petalets)

23 Jan 2014

5

Pipes

Tool for pipe bending manufactured and already used at DESY successfully Pipes undergoing brazing of StSt fittings (did that already for the petalets) Barely enough pipes for 5 petals, would join common order

23 Jan 2014

6

High T conductivity foam

Allcomp foam in hand at DESY, enough for ~10 petals Allcomp K9 130 ppi

• 0.23 g/cc, 20 W/m·K min (measured ~ 0.22 g/cc, 40 W/m·K by Allcomp on our piece) Gluing of pipe into foam?

• Pre-sealing foam (BNL’s approach)?• Follow petalet approach (glue dispensing with syringe on foam)?• No strong preference from my side

23 Jan 2014

7

E breaks

Will not be included for now

23 Jan 2014

8

Top and bottom closeouts

Top and bottom closeouts already manufactured at DESY (4 sets) Diameter for E break too tight! Caused some cracking in several samples

• Will adjust to 2.3 mm OD in next round, since E breaks will not be included Slight bending on the longest part

• We still need to characterize the extent of it Annealing of PEEK as suggested by our US colleagues Simplified annealing procedure, since we don’t have a climate chamber (or an

autoclave) that goes so high in T Slowly increase T up to 149 and then to 200

23 Jan 2014

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14:32 22:53 7:14 15:35 23:56 8:17 16:38 0:59

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PEEK Full Anneal in Tenney JR Environmental Chamber 19 x 152 x 152 mm plate

CH1Act

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9

C-channels

CF C-channels already in hand, maufactured at Liverpool by T. Jones and L. Poley Just received them, not yet characterized, but they look nice and flat Were they measured in Liverpool? Enough for 1 petal

Next set of C-channels to be manufactured in PEEK at DESY, any objections to that?

23 Jan 2014

10

Locking points

Being worked out at Valencia, see David’s slides for details

23 Jan 2014

11

Core gluing

Set of tool currently under manufacture or under design Based on precision pins for alignment among them and the petal facesheets In manufacture:

• Main base plate (+ lid) and mirrored base plate All tools align against this one

• Top and bottom closeouts gluing tools• Facing cutting tool

Finishing the design:• Foam gluing tool• HC gluing (if any)• C-channel gluing tools

No clear solution for locking points gluing, manual procedure for now

23 Jan 2014

12

Core gluing tools

23 Jan 2014

13

Dummy sensors, hybrids, ASICs

Dummy sensors 6” (plain) wafers in hand next week at IMB-CNM (Barcelona) Laser cutting undergoing final tests (straight cuts) Sandblast cutting being investigated too

Dummy ASICs with heaters Currently in fabrication at IMB-CNM, delivery in < 2 weeks

Dummy hybrids A few R0 H1 hybrids already in hand at Freiburg Tooling for R0 in manufacture at Freiburg Given the delays due to the accident at the foundry, it doesn’t seem feasible to have

all flavors in hand in reasonable timescale for TM I suggest FR4 dummies once the design of all flavors is finished

• If agreed, should Zeuthen do it?

23 Jan 2014

14

DCDC (power board) and EoP dummies

Manufactured in FR4 Status?

23 Jan 2014

15

Open issues

Mechanical characterization of petal cores Should we follow Valencia’s recipe from previous core (~2009)?

• Where? I would rather do it at DESY and Valencia• I have to figure out if we have the necessary equipment at DESY

Thermal characterization Figure it out soon

• Where? I guess DESY?

Assembly of dummies Tools? Manual? I guess this is the more realistic approach

Industry approach for petal core manufacture investigated at Valencia Will need raw materials for that DESY can provide N636 HC and (a bit of) Allcomp foam Other materials? Joint order?

23 Jan 2014