1 Assembly procedure for PETS and AS 11-July-2011 Assembly procedure of PETS and AS for T0 module Lab F. Rossi PETS AS 2 Assembly procedure for PETS and AS TABLE OF CONTENTS 1.PETS Introduction Assembly procedure Traveller 2.AS Introduction Assembly procedure Traveller 3 Assembly procedure for PETS and AS TABLE OF CONTENTS 1.PETS Introduction Assembly procedure Traveller 2.AS Introduction Assembly procedure Traveller 4 Assembly procedure for PETS and AS 1. PETS: introduction Vacuum flange with adapter Damped bars Tank (short) Coupler middle mm mm 202 mm Coupler extremity Frictional contact Frictional contact EBW Tank 5 Assembly procedure for PETS and AS 1. PETS: assembly procedure Ar brazing (AuCu 25/75, 1040 C) Ar brazing (AuCu 25/75, 1040 C) TIG welding Ar brazing (AuCu 25/75, 1040 C) Ar brazing (AuCu 25/75, 1040 C) EBW 1. PETS: assembly procedure Workflow Machining Coupler with on-off Chamber for on- off mechanism Tank (short) Tank Vacuum flange with adapter Coupler (middle) Coupler (extremity) 6 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps (I) MACHINING & DELIVERY (I) MACHINING & DELIVERY (III) CLEANING 1.Degreasing + deoxidation + passivationDegreasing + deoxidation + passivation (III) CLEANING 1.Degreasing + deoxidation + passivationDegreasing + deoxidation + passivation (VI) TIG WELDING 1.Fixed UHV flange + tube + minitank tube (short)Fixed UHV flange + tube + minitank tube (short) 2.Fixed UHV flange + tube + minitank tubeFixed UHV flange + tube + minitank tube (VI) TIG WELDING 1.Fixed UHV flange + tube + minitank tube (short)Fixed UHV flange + tube + minitank tube (short) 2.Fixed UHV flange + tube + minitank tubeFixed UHV flange + tube + minitank tube (V) MACHINING 1.Coupler with on-off (x2)Coupler with on-off (x2) (V) MACHINING 1.Coupler with on-off (x2)Coupler with on-off (x2) (VII) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.Coupler extremityCoupler extremity 2.Coupler middleCoupler middle (VII) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.Coupler extremityCoupler extremity 2.Coupler middleCoupler middle (VIII) EBW 1.PETS unitPETS unit (VIII) EBW 1.PETS unitPETS unit (X) CONDITIONING (X) CONDITIONING (IX) LEAK TEST (IX) LEAK TEST (IV) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.2 minitank rings + minitank tube (short)2 minitank rings + minitank tube (short) 2.2 minitank rings + minitank tube2 minitank rings + minitank tube 3.Chamber for on-off mechanism (x2)Chamber for on-off mechanism (x2) 4.Coupler with on-off half 1 + half 2 (x2)Coupler with on-off half 1 + half 2 (x2) 5.Adapter disk 3 + DN rotat. flange (insert )Adapter disk 3 + DN rotat. flange (insert ) (IV) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.2 minitank rings + minitank tube (short)2 minitank rings + minitank tube (short) 2.2 minitank rings + minitank tube2 minitank rings + minitank tube 3.Chamber for on-off mechanism (x2)Chamber for on-off mechanism (x2) 4.Coupler with on-off half 1 + half 2 (x2)Coupler with on-off half 1 + half 2 (x2) 5.Adapter disk 3 + DN rotat. flange (insert )Adapter disk 3 + DN rotat. flange (insert ) (II) QUALITY CONTROL 1.Inlet inspectionInlet inspection (II) QUALITY CONTROL 1.Inlet inspectionInlet inspection 7 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: Machining & Quality control GENERAL REQUIREMENTS Dimensional tolerances: 0.01 mm Geometrical tolerances: 0.01 mm Roughness (Ra): 0.1 m The inspection takes place in specific room, with all the important issues (clean air, gloves, shoes with gloves, specific glasses and specific machines), in order to check the surface for scratches, dents, pits, cracks. The pieces are also organized in photo archives. If parts are not clean enough, cleaning procedure should be done again. If parts are not clean, measurement cant be done because any oil or dust could have an influence on measurement machines. II. QUALITY CONTROL I. MACHINING 8 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: Cleaning 1.Unpacking, visual inspection, fixing of the plastic hook or appropriate support 2.Degreasing with detergent NGL spec. ALU III and ultrasounds Concentration: 10 g/l Temperature: 50 C Time: minutes 3.Rinsing with water jet and by immersion 4.Pickling (deoxidation) with hydrochloric acid Concentration: 50 % Temperature: room Time: 10 20 seconds 5.Rinsing with water jet and by immersion 6.Passivation with chromic acid Concentration: o Chromic acid: 70 80 g/l o Sulphuric acid: 3 ml/l Temperature: room Time: seconds (etching of about 0.3 m) 7.Rinsing with water jet and by immersion 8.Final rinsing with demineralised water and ultrasound, followed by rinsing with ethylic alcohol 9.Drying with filtered air or nitrogen 10.Drying in an oven Temperature: 60 C Time: 5 10 minutes 11.Packaging with tissue paper and plastic bubble paper III. CLEANING 9 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: Brazing IV. ARGON BRAZING (Au/Cu 25/75, 1040 C) Furnace brazing is a production process for joining the components of small assemblies with a metallurgical bond, using a nonferrous filler metal as the bonding material and a furnace as the heat source. Capillary flow is the dominant physical phenomenon that ensures good brazements. Assembly before brazing Transport to furnace Outgassing Brazing Before each brazing cycle, an outgassing cycle is performed to eliminate contaminants and gases coming from a material when subjected to a vacuum environment. Brazing temperature history 10 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: Brazing Graphite plate ab cd Ceramic support Ceramic plate WEIGHT Brazing wire groove (Au/Cu 25/75, 1 mm) Pins seats for alignment of the two halves before brazing Pins insertion for alignment IV. ARGON BRAZING (Au/Cu 25/75, 1040 C) Assembly before brazing On-off main body (x2) 11 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: TIG welding & Machining Plate a. Tube b. TIG welding of fixed UHV flange and tube c. Preparation for the next step d. Positioning of tank previously brazed Plate e. TIG welding V. TIG WELDING: tanks VI. MACHINING: couplers with on-off Couplers with on-off are machined with reference to RF flanges dimensions, in order to achieve a clearance of mm between the two surfaces where the brazing alloy will flow and create the joint. 12 Assembly procedure for PETS and AS 1. PETS: assembly procedure Ar brazing (AuCu 25/75, 1040 C) Ar brazing (AuCu 25/75, 1040 C) TIG welding Ar brazing (AuCu 25/75, 1040 C) Ar brazing (AuCu 25/75, 1040 C) EBW 1. PETS: assembly procedure Workflow Machining Coupler with on-off Chamber for on- off mechanism Tank (short) Tank Vacuum flange with adapter Coupler (middle) Coupler (extremity) 13 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: Brazing VII. ARGON BRAZING (Au/Cu 25/75, 1040 C) Chamber for on- off mechanism Cooling adapters RF flange Vacuum flange Pins Plug Adapter disk Beam pipe Coupler (extremity) Coupler (middle) 14 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: EBW VIII. EBW Electron-Beam Welding (EBW) is a high-energy density fusion process that is accomplished by bombarding the joint to be welded with an intense (strongly focused) beam of electrons. The instantaneous conversion of the kinetic energy of these electrons into thermal energy as they impact and penetrate into the workpiece on which they are impinging causes the weld-seam interface surfaces to melt and produces the weld-joint coalescence desired. Welding Bearing Chuck driven by the welding machine Fixed V-support Ground 15 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: EBW Bearing Upper eye-bolt Upper bolt Upper cap cover Lateral eye-bolt Holding- device Lower cap cover Lower bolt Lateral eye-bolt Nut Threaded rod Nut Bearing: allow EBW tooling rotation around its axis, once it is positioned on the EBW machine. Upper cap cover: apply clamping force to PETS unit, once the nut is screwed on the threaded rod. Upper bolt: fix upper cap cover and coupler (extremity). Eye-bolts: for lifting and handling. Threaded rod (M16): connection between the upper and the lower cap cover. Lower cap cover: sustain PETS unit during the assembly on the tooling. Lower bolt: fix lower cap cover and vacuum flange with adapter. Nut (M16): after it is screwed using a torque spanner, a compressive axial load is applied to PETS units (while the rod has tensile stresses). Holding device: fix axial and angular position of tanks. VIII. EBW: tooling 16 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: EBW 1. The lower cap cover is positioned on the assembly table 2. The lower bolt is fastened in order to fix the lower cap cover to the vacuum flange with adapter 3. The first damped bar is inserted into the vacuum flange with adapter 4. Positioning of tank (short) 5. Positioning of coupler (middle) VIII. EBW: assembly on tooling Pins are inserted in damping blocks Damping blocks are positioned inside mock-up bars Damping blocks are fixed using holder plates 17 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: EBW 6. The second damped bar is inserted into the coupler (middle) 7. Positioning of tank8. Positioning of coupler (extremity) 9. Threaded rod is inserted and the upper cap cover is positioned VIII. EBW: assembly on tooling 18 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: EBW VIII. EBW: assembly on tooling 35 m 140 m PROBLEM 19 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: EBW Olivetti 4 axis Dimensions: 1600x900x600 mm Accuracy 3 m VIII. EBW: fiducialisation SOLUTION Alignment of subassemblies with respect to a common axis Fiducials Fiducialisation 20 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: EBW Romer arm Accuracy: 7 m VIII. EBW: assembly on tooling Fiducials are measured by means of the Romer arm Adjustments along the radial direction are realised on the basis of the previous measurements and using a reference column Clamping force is applied The position of the axis for each subassembly is derived 21 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: EBW 10. Angular and axial position of tanks is measured, then the holding device is fixed VIII. EBW: assembly on the tooling 11. Verification of the final alignment and then tack welding 12. Rotation and transportation to the EBW machine. The holding device is removed. 22 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: EBW 13. PETS unit is removed from the EBW tooling PLATE 14. Tube fittings are inserted 15. U-cooling tube is inserted VIII. EBW: post-assembly 23 Assembly procedure for PETS and AS 1. PETS: assembly procedure Steps: Leak test & Conditioning IX. Leak test X. Conditioning Leak detector and N 2 are used to test vacuum efficiency. PETS unit is positioned inside a vessel with a protective atmosphere (N 2 ) inside to prevent copper oxidation. 24 Assembly procedure for PETS and AS 1. PETS: traveller 25 Assembly procedure for PETS and AS 1. PETS: traveller 26 Assembly procedure for PETS and AS TABLE OF CONTENTS 1.PETS Introduction Assembly procedure Traveller 2.AS Introduction Assembly procedure Traveller 27 Assembly procedure for PETS and AS 2. AS: introduction Cooling circuit Vacuum flange RF flange Manifold Interconnection flange RF waveguide Accelerating structure Super-accelerating structure Target sphere 28 Assembly procedure for PETS and AS 2. AS: introduction Manifold cover with vacuum flange STACK (4 accelerating structures) Disks stack Manifold small cover WG damping interface WFM Manifolds 29 Assembly procedure for PETS and AS 2. AS: assembly procedure Workflow IV. Ar brazing (AuCu 25/75, 1040 C) IV. Ar brazing (AuCu 25/75, 1040 C) V. Machining VI. Ar brazing (AuCu 25/75, 1040 C) VI. Ar brazing (AuCu 25/75, 1040 C) VII. Ar brazing (AuCu 35/65, 1020 C) VII. Ar brazing (AuCu 35/65, 1020 C) VIII. Ar brazing (AuCu 50/50, 980 C) VIII. Ar brazing (AuCu 50/50, 980 C) IX. EBW Stack type 1 Stack type 2 Structure type 1 Structure type 2 30 Assembly procedure for PETS and AS 2. AS: assembly procedure Workflow IV. Ar brazing (AuCu 25/75, 1040 C) IV. Ar brazing (AuCu 25/75, 1040 C) V. Machining VI. Ar brazing (AuCu 25/75, 1040 C) VI. Ar brazing (AuCu 25/75, 1040 C) VII. Ar brazing (AuCu 35/65, 1020 C) VII. Ar brazing (AuCu 35/65, 1020 C) VIII. Ar brazing (AuCu 50/50, 980 C) VIII. Ar brazing (AuCu 50/50, 980 C) IX. EBW Stack type 1 Stack type 3 Structure type 1 Structure type 3 31 Assembly procedure for PETS and AS 2. AS: assembly procedure Workflow IX. EBW (covers) X. EBW (2 stacks) X. EBW (2 stacks) 32 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps (I) MACHINING & DELIVERY (I) MACHINING & DELIVERY (III) CLEANING 1.Degreasing + deoxidation + passivationDegreasing + deoxidation + passivation (III) CLEANING 1.Degreasing + deoxidation + passivationDegreasing + deoxidation + passivation (V) MACHINING 1.WFM WG brazed (x32=4x8)WFM WG brazed (x32=4x8) 2.WG damping interface (x32=4x8)WG damping interface (x32=4x8) (V) MACHINING 1.WFM WG brazed (x32=4x8)WFM WG brazed (x32=4x8) 2.WG damping interface (x32=4x8)WG damping interface (x32=4x8) (VI) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.Manifold (hor) assembly (x8=1x8)Manifold (hor) assembly (x8=1x8) 2.Hor. manifold (mirrored) assembly (x8=1x8)Hor. manifold (mirrored) assembly (x8=1x8) 3.Vert. manifold assembly (x16=8x2)Vert. manifold assembly (x16=8x2) (VI) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.Manifold (hor) assembly (x8=1x8)Manifold (hor) assembly (x8=1x8) 2.Hor. manifold (mirrored) assembly (x8=1x8)Hor. manifold (mirrored) assembly (x8=1x8) 3.Vert. manifold assembly (x16=8x2)Vert. manifold assembly (x16=8x2) (XII) EBW 1.MB assemblyMB assembly (XII) EBW 1.MB assemblyMB assembly (XIV) CONDITIONING (XIV) CONDITIONING (XI) LEAK TEST (XI) LEAK TEST (IV) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.WFM WG cover + WFM WG body (x32=4x8)WFM WG cover + WFM WG body (x32=4x8) 2.Waveguide damping interface half 1 + half 2 (x32=4x8)Waveguide damping interface half 1 + half 2 (x32=4x8) 3.Stack type 1 (x6)Stack type 1 (x6) 4.Stack type 2 (x1)Stack type 2 (x1) 5.Stack type 3 (x1)Stack type 3 (x1) 6.Manifold cover (tank int.) + vacuum tube P1 (x8)Manifold cover (tank int.) + vacuum tube P1 (x8) 7.Manifold small cover 3 + small cover 3 insert (x32=4x8)Manifold small cover 3 + small cover 3 insert (x32=4x8) (IV) ARGON BRAZING (Au/Cu 25/75, 1040 C) 1.WFM WG cover + WFM WG body (x32=4x8)WFM WG cover + WFM WG body (x32=4x8) 2.Waveguide damping interface half 1 + half 2 (x32=4x8)Waveguide damping interface half 1 + half 2 (x32=4x8) 3.Stack type 1 (x6)Stack type 1 (x6) 4.Stack type 2 (x1)Stack type 2 (x1) 5.Stack type 3 (x1)Stack type 3 (x1) 6.Manifold cover (tank int.) + vacuum tube P1 (x8)Manifold cover (tank int.) + vacuum tube P1 (x8) 7.Manifold small cover 3 + small cover 3 insert (x32=4x8)Manifold small cover 3 + small cover 3 insert (x32=4x8) (II) QUALITY CONTROL 1.Inlet inspectionInlet inspection (II) QUALITY CONTROL 1.Inlet inspectionInlet inspection (VII) ARGON BRAZING (Au/Cu 35/65, 1020 C) 1.Structure type 1 (x6)Structure type 1 (x6) 2.Structure type 2 (x1)Structure type 2 (x1) 3.Structure type 3 (x1)Structure type 3 (x1) (VII) ARGON BRAZING (Au/Cu 35/65, 1020 C) 1.Structure type 1 (x6)Structure type 1 (x6) 2.Structure type 2 (x1)Structure type 2 (x1) 3.Structure type 3 (x1)Structure type 3 (x1) (VIII) ARGON BRAZING (Au/Cu 50/50, 980 C) 1.Brazed stack 1 + AS cooling fitting adaptersBrazed stack 1 + AS cooling fitting adapters 2.Brazed stack 2 + AS cooling fitting adaptersBrazed stack 2 + AS cooling fitting adapters (VIII) ARGON BRAZING (Au/Cu 50/50, 980 C) 1.Brazed stack 1 + AS cooling fitting adaptersBrazed stack 1 + AS cooling fitting adapters 2.Brazed stack 2 + AS cooling fitting adaptersBrazed stack 2 + AS cooling fitting adapters (IX) EBW 1.Stack 1Stack 1 2.Stack 2Stack 2 (IX) EBW 1.Stack 1Stack 1 2.Stack 2Stack 2 (X) TIG WELDING 1.MB interconnection flange + stack 1MB interconnection flange + stack 1 2.MB interconnection flange + stack 2MB interconnection flange + stack 2 (X) TIG WELDING 1.MB interconnection flange + stack 1MB interconnection flange + stack 1 2.MB interconnection flange + stack 2MB interconnection flange + stack 2 x32 x8 x6x1 x32 x8 x16 x6 x1 (XIII) LEAK TEST (XIII) LEAK TEST 33 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 1st brazing Brazing wire seat (Au/Cu 25/75, 0.7 mm) IV. ARGON BRAZING (Au/Cu 25/75, 1040 C) Assembly on the V-shape column 34 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 1st brazing Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate 1 x CLIATLAS01081 x CLIATLAS01071 x CLIATLAS x CLIATLAS x CLIATLAS x CLIATLAS0099 IV. ARGON BRAZING (Au/Cu 25/75, 1040 C) Assembly on the V-shape column 35 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 1st brazing Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic WEIGHT 1 x CLIATLAS x CLIATLAS x CLIATLAS01031 x CLIATLAS x CLIATLAS0106 Ceramic plate and weight are positioned on the top of the structure IV. ARGON BRAZING (Au/Cu 25/75, 1040 C) Assembly on the V-shape column 36 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 1st brazing Once the assembly procedure is completed, straightness measurements are performed using the Mitutoyo Linear Height LH-600. The measurements are done with the accelerating structure on the V- support and considering two reference lines, called REF A and REF B. The measurement is done before and after transport to the oven and they are organized in charts. REF A REF B IV. ARGON BRAZING (Au/Cu 25/75, 1040 C) Straightness measurements Mitutoyo Linear Height LH-600 Measuring range: mm Resolution: 0.1 m Accuracy: ( L[mm]/600) m Measuring force: 1N 37 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 1st brazing IV. ARGON BRAZING (Au/Cu 25/75, 1040 C) I. A rectangular plate is used to preserve the alignment of the structure during the transport inside the oven II. The rectangular plate is fastened to the V-support using screwed bar III. The disks stack is transported inside the furnace IV. The disks stack is inside the furnace V. Load is applied to the disks stack using the load device and thermocouples are mounted to measure the temperature history during the heat treatment. The alignment is checked for the last time before the brazing process. Transportation to furnace 38 Assembly procedure for PETS and AS 2. AS: assembly procedure Workflow IV. Ar brazing (AuCu 25/75, 1040 C) IV. Ar brazing (AuCu 25/75, 1040 C) V. Machining VI. Ar brazing (AuCu 25/75, 1040 C) VI. Ar brazing (AuCu 25/75, 1040 C) VII. Ar brazing (AuCu 35/65, 1020 C) VII. Ar brazing (AuCu 35/65, 1020 C) VIII. Ar brazing (AuCu 50/50, 980 C) VIII. Ar brazing (AuCu 50/50, 980 C) IX. EBW Stack type 1 Stack type 2 Structure type 1 Structure type 2 39 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 2nd brazing VI. ARGON BRAZING (Au/Cu 25/75, 1040 C) Reference surface V-shape column Grooves for brazing alloy wires Manifolds are assembled using one of the two flat surfaces of the V-shape column Assembly on the V-shape column 40 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 2nd brazing VI. ARGON BRAZING (Au/Cu 25/75, 1040 C) Ceramic support Inox plate Ceramic support Inox plate Ceramic support Inox plate Ceramic support Inox plate x CLIATLAS01021 x CLIATLAS x CLIATLAS x CLIATLAS0110 Assembly on the V-shape column 41 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 2nd brazing VI. ARGON BRAZING (Au/Cu 25/75, 1040 C) Ceramic support Inox plate Ceramic support Inox plate Ceramic support Inox plate Ceramic support Inox plate x CLIATLAS01111 x CLIATLAS x CLIATLAS x CLIATLAS0113 Assembly on the V-shape column 42 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 2nd brazing VI. ARGON BRAZING (Au/Cu 25/75, 1040 C) Ceramic support Inox plate Ceramic support Inox plate Ceramic support Inox plate Ceramic support Inox plate x CLIATLAS00321 x CLIATLAS0102 Ceramic plate WEIGHT WeightAlignment check Ceramic plate WEIGHT Assembly on the V-shape column 43 Assembly procedure for PETS and AS 2. AS: assembly procedure Workflow IV. Ar brazing (AuCu 25/75, 1040 C) IV. Ar brazing (AuCu 25/75, 1040 C) V. Machining VI. Ar brazing (AuCu 25/75, 1040 C) VI. Ar brazing (AuCu 25/75, 1040 C) VII. Ar brazing (AuCu 35/65, 1020 C) VII. Ar brazing (AuCu 35/65, 1020 C) VIII. Ar brazing (AuCu 50/50, 980 C) VIII. Ar brazing (AuCu 50/50, 980 C) IX. EBW Stack type 1 Stack type 2 Structure type 1 Structure type 2 44 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 3rd brazing Rod Nut Lower plate Lateral support Lateral spring Lateral plate Upper support Upper spring Wedges Lower plate (graphite): support the assembly during alignment operations and brazing cycle. Wedges (ceramic): allow small adjustment of manifolds in the vertical direction. Lateral springs (graphite): apply an horizontal force to the manifolds through the lateral plates and allow thermal expansion of the assembly during the brazing cycle (k=20 N/mm). Lateral supports (stainless steel): support the springs. Upper spring (graphite): apply a vertical force on the manifolds through the upper support and allow thermal expansion of the assembly during the brazing cycle. Rod (stainless steel): connect upper support and lower plate. VII. ARGON BRAZING (Au/Cu 35/65, 1020 C) Tooling 45 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 3rd brazing 1. Graphite plate2. Disks stack3. Wedges4. Manifolds 5. Lateral supports, plates and springs 6. Upper support7. Rod 8. Upper spring and nut VII. ARGON BRAZING (Au/Cu 35/65, 1020 C) Assembly on the tooling 46 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 3rd brazing VII. ARGON BRAZING (Au/Cu 35/65, 1020 C) Fiducialisation Brazed structureFiducials (considering that another brazing step is required) Fiducialisation 47 Assembly procedure for PETS and AS 2. AS: assembly procedure Workflow IV. Ar brazing (AuCu 25/75, 1040 C) IV. Ar brazing (AuCu 25/75, 1040 C) V. Machining VI. Ar brazing (AuCu 25/75, 1040 C) VI. Ar brazing (AuCu 25/75, 1040 C) VII. Ar brazing (AuCu 35/65, 1020 C) VII. Ar brazing (AuCu 35/65, 1020 C) VIII. Ar brazing (AuCu 50/50, 980 C) VIII. Ar brazing (AuCu 50/50, 980 C) IX. EBW Stack type 1 Stack type 2 Structure type 1 Structure type 2 48 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 4th brazing VIII. ARGON BRAZING (Au/Cu 50/50, 980 C) Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic Inox plate Ceramic WEIGHT 1. Intermediate piece 2 2. Brazed stack 13. Brazed stack 1 and alignment check 4. Brazed stack 1 and alignment check 5. Brazed stack 2 and alignment check 6. Interconnection bellow (BR) and final alignment check 7. AS-cooling fitting adapters and weight The alignment between two consecutive stacks must be done with reference to the outside diameters of the disks 3 DOF Reference lines for straightness measurements using Mituyoyo Linear Height Assembly 3 DOF 49 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 4th brazing VIII. ARGON BRAZING (Au/Cu 50/50, 980 C) Tooling and alignment 1 st structure2 nd structure and measurement Auxiliary frameAlignment3 rd structure 4 th structure 50 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: 4th brazing VIII. ARGON BRAZING (Au/Cu 50/50, 980 C) Fiducialisation Fiducials Brazed stack Fiducialisation 51 Assembly procedure for PETS and AS 2. AS: assembly procedure Workflow IV. Ar brazing (AuCu 25/75, 1040 C) IV. Ar brazing (AuCu 25/75, 1040 C) V. Machining VI. Ar brazing (AuCu 25/75, 1040 C) VI. Ar brazing (AuCu 25/75, 1040 C) VII. Ar brazing (AuCu 35/65, 1020 C) VII. Ar brazing (AuCu 35/65, 1020 C) VIII. Ar brazing (AuCu 50/50, 980 C) VIII. Ar brazing (AuCu 50/50, 980 C) IX. EBW Stack type 1 Stack type 2 Structure type 1 Structure type 2 52 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: EBW Manifold cover 2 assembly (x16) Manifold small cover assembly (x16) Manifold cover simple (x12) Manifold cover with vacuum flange (x4) IX. EBW: covers Damping material 12 53 Assembly procedure for PETS and AS 2. AS: assembly procedure Workflow IX. EBW (covers) X. EBW (2 stacks) X. EBW (2 stacks) 54 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: EBW XII. EBW: 2 stacks Alignment x y z xx 55 Assembly procedure for PETS and AS 2. AS: assembly procedure Steps: EBW XII. EBW: 2 stacks Screw Vacom MFA-412 (x8) g. Intermodule interconnection DM (x2) f. Cooling tube type 4 (x16) e. Cooling tube type 3 (x8) d. Cooling tube type 1 (x4) c. Swagelok SS-8M0-5-4PR (x56) b. Swagelok B-8M0-1-4RP with CU gasket (x8) Post-assembly of cooling circuits 56 Assembly procedure for PETS and AS 2. AS: traveller 57 Assembly procedure for PETS and AS 2. AS: traveller