limadou hepd-02 tracker cold plate prototypes production ... · 17/03/2020 corrado gargiulo |...

LIMADOUHEPD-02 TRACKER

Cold plate prototypes production and preliminary test

Corrado Gargiulo

Massimo Angeletti

March 2020

Outline

17/03/2020 Corrado Gargiulo | LIMADOU Turrets Cold plate preliminary tests 2

LIMADOU Stave mechanics Cold plate

o N. 6 Cold plate producedo CP1=HEPD02_D0_1

o CP2=HEPD02_D1_1

o CP3=HEPD02_D1_2 (cut to samples)

o CP4=HEPD02_D1_3

o CP5=HEPD02_D1_4 (cut to samples)

o CP6=HEPD02_D1_5

o Preliminary Test o On Cold plate

o Planarity (CP3, CP6) DONE

o Bending (CP1) DONE

o Modal (CP2) DONE

o Heat cycle (CP1) DONE

o CTE (CP1, CP2) DONE

o On Coldplate+ End Blocks

o Modal (CP2) (DONE)

o Heat cycle (CP2) (DONE)

o CTE (CP2) (DONE)

Layout

LIMADOU Mechanical Stave


• Nomenclature:

196mm

Cold plate (CP)

Mechanical Stave (MS)

Silvia Coli

Silvia Coli

34.6mm

Layout• CFRP Materials and Glue

Coldplate CFRP: prepreg K13D2U

Glue Cold plate/End Blocks interface: Masterbond EP37-3FLFAO Technical Data Sheet (link)

Note: Glass fleece to be added at the interface with connectors to prevent galvanic corrosion, or anodize end-block (unsealed MIL A 8625 Type III). Not applied in the prototypes.

Note: Parylene coating can be considered for electrical insulation but it will sensibly lower the peel strength. Suggestion is to relay on the electrical isolation by colplate resin and the glue for chips. Specific test can be foreseen

Materials


Carbon fleecek13D2U

Number of filaments per carbon thread 2000. FAW Fibre Areal Weight 120 g/m2. 33% resin content. Resin Cyanate ester EX1515.

Carbon Unidirectional Prepreg: R-EX1515/K1D2U 2K Carbon Fleece

Carbon fibre mats 8g/m2

Filaments[K=1000]

E1[GPa]

Xt /Xc

[MPa]E2

[GPa]Yt

[MPa]K

[W/mK]CTE

[10-6K-1]K13D2U [0] fibre 2K 935 3688 800 -1,1

E[GPa]

Xt

[GPa]HT fiber

240 4,4

Layout• Design 0:

#1 CP produced: CP2=HEPD02_D0_1

Cold Plate


0.4 mm

2.0 mm

0°

Ply Material/sub-laminate

Thickness(mm)

Orientation(deg)

Number

Fleece 0.02 1

K13D2U_EX1515 0.120 90 1

K13D2U_EX1515 0.120 0 1

K13D2U_EX1515 0.120 90 1

Fleece 0.02 1

Total 0.4

• Flat part


Thickness(mm)

Orientation(deg)

Number

Fleece 0.02 1

K13D2U_EX1515 0.120 16

Fleece 0.02 1

Total 2

• Lateral part

30.6 mm

34.6 mm

6.6 mm

Layout• Design 1:

Rib thickness from 2.0 to 1.9mm

CP width unchanged 34.6mm

#5 CP produced: CP2=HEPD02_D1_1

CP3=HEPD02_D1_2

CP4=HEPD02_D1_3

CP5=HEPD02_D1_4

CP6=HEPD02_D1_5

Cold Plate


0°

90°

196mm

1.9 mm30.8 mm

34.6 mm0.4 mm

6.6 mm


Thickness(mm)

Orientation(deg)

Number

Fleece 0.02 1

K13D2U_EX1515 0.120 90 1

K13D2U_EX1515 0.120 0 1

K13D2U_EX1515 0.120 90 1

Fleece 0.02 1

Total 0.4

• Flat part


Thickness(mm)

Orientation(deg)

Number

Fleece 0.02 1

K13D2U_EX1515 0.120 15

Fleece 0.02 1

Total 1.9

• Lateral part

Test• Planarity test

Objective: CP flatness investigation

Test article: Cold plate (#3,#6)

Test procedure:

Equipment: Mitutoyo Crystal apex 7106,

QVP Camera (Optical probe)

Cold Plate #3, #6


Planarity <0.100mm

Tolerance zone 0.082 mmUpper Tol. 0.038Lower Tol. -0.044

No. of pts. 84Min./Max. Pnt. 82/41Std. dev. *4 0.075Flatness 0.082

EP-DT Detector technologies

Tolerance zone 0.054 mmUpper Tol. 0.025Lower Tol. -0.029

No. of pts. 84Min./Max. Pnt. 77/1Std. dev. *4 0.087Flatness 0.054

PlaneTolerance ZoneMin/ Max Points

CP#6

CP#3

Test• 3 Point bending test:

Objective: Elastic properties

Test article: Cold plate (#)

Test procedure: tested up to 200gf

Linear behaviour; EIequivalent=9.37 106 Nmm2

Cold plate #1


No plastic deformation observed (marble table) No visual damages have been detected (microscope)

• Bending test:Objective: Plastic behaviour

Test article: Cold plate (#1)

Test procedure: Gradually tested up to 780gf (Safety Margin x Load Factor x payload)

Distributed weight over a surface

(longitudinal and transversal)


0.00

0.01

0.02

0.03

0.04

0 25 50 75 100 125

Dis

pl.

[m

m]

Force [gf]

3points bending test

Before[mm]

Linear(Before[mm])

Test• Bending test before and after heat cycle:

Objective: Resistance to heat load

Test article: Cold plate (#1)

Test procedure: 1 cycle (65°C)

Planarity inspection before and after.

Tested up to 200gf (50 gr steps)

Cold plate #1


No damages or plastic deformations have been detected Same mechanical properties before and after

0.000.010.020.030.040.050.060.070.080.09

0 100 200 300

Dis

pl.

[mm

]

Force [gf]

3points bending test

Before

After_1

After_2


0

10

20

30

40

50

60

70

0 10 20 30 40

[°C

]

[min]

Temperature-Time

10 min65 °C

25 °C

Test

Test set-up: CTE


Set-up used to measure the Cold plate CTE and the strain at the interface Cold plate/End blocks

• CTE measurements set-up 1:

EN MME Mechanical Measurements Laboratory

• Cameras: Manta MG-505B• Resolution: 2452*2056 pixels• Lenses: Ricoh FL-CC5028-2M• Focal Length: 50 mm• Aperture: f8

• Field of View: ≈ 180*100 mm• Pixels per mm: ≈7• Facet size: 19 pixel ≈ 2.7 mm• Grid Spacing: 11 pixel (33% overlap)

Test procedure: performed in a laboratory furnace (heating rate 0.5 °C/min). • 3 temperature sensors attached to the back surface of the CP.• Digital image correlation system to observe the strain*. Equipment: • France Etuves XFL050 (laboratory furnace). • PT100 sensors. • DANTEC Q400 3D (digital image correlation system) configured according to the

following parameters:

(link)

*White pattern for visual recognition

https://edms.cern.ch/document/2320154/1/approvalAndComments

Test

Test set-up: CTE


Set-up used for to measure the CTE of specimens

• CTE measurements set-up 2:


Dilatometer DIL 402 E

The transfer of current between the primary and the secondaries of the LVDT displacement transducer is controlled by the position of a magnetic core

An LVDT Displacement Transducer comprisesa primary (A) and two secondaries (B) coils

Test procedure: Cold plate specimens of side ribs and plate measured in the dilatometer while changing temperatureEquipment: Dilatometer DIL 402 E

Test• CTE measurement test (preliminary)

Objective: Evaluate CTE in X,Y directions

Test article: Cold plate (#2) only, no end-blocks

Test procedure: ramp 0.5 °C/min

Set-up: CTE Test setup 1

Cold plate #1, #2


CTEs < 1.5 ppm·C-1 ; test at the setup limit*

Applying linear regression to the strain-temperature curve

CTE = 1.3 (CP #1) 0.9 (CP #2) ppm·C-1 in X Direction CTE = 0.6 (CP #1) 0.5 (CP #2) ppm·C-1 in Y Direction


YX

*Test repeated in set-up 2

CP#1

CP#2

CP#1

CP#2

Test• CTE measurement test (preliminary)

Objective: Evaluate CTE in X,Y directions

Test article: n.6 Samples (#S#) from Cold plate (#3)

Test procedure: 70 °C, ramp 0.5 °C/min


Specimens Cold Plate#3


CP long <4 ppm·C-1 ; CP trans <2 ppm·C-1 ; CTE rib <3 ppm·C-1

Rib (longitudinal)

Cold plate (transversal)

Cold plate (longitudinal)


(link)

From 30C to 80C From 80C to 20C

Ex. Test behavior (rib S2)


Test• Strain

Objective: determine the thermally induced strains in the surface of the colplate due to differential expansion of both materials

Test article: Cold plate +End blocks

• Test procedure: ramp 0.5 C/min. Use of only one temperature sensor per specimen bonded with kaptontape to the back face of the aluminum connectors


Cold plate #1; Cold plate #2


1000-5000 micron/m @ 60 °C,

Araldite 2011 (used only for comparison)

Test results

Masterbond EP37-3FLFAO

The asymmetry observed between both sides of the colplates could be due to contact conduction

between the supporting structures and the connectors of the colplate. It is agreed to perform an

additional measurement over colplate 2 with special attention to avoid conduction between the

connectors and the supporting structures, and allowing a better view on the rib of the specimen.

(link)


σ = 200MPa x 5/1000 = 1MPa; 4.8MPa tensile lap shear; 20 MPa tensile


Test• Heat Cycle test

Objective: Resistance to heat load cycles

Test article: Cold plate (#1) +Araldite2011 + End Blocks

Test procedure: 3 cycles (80, 100, 120 °C), (5 °C/min)

Between cycles, evaluation of:

- End-blocks/Cold plate interface (microscope), - planarity inspection on marble table.

Cold plate #1


No interface damages have been detected.

0

20

40

60

80

100

120

140

0 20 40 60 80 100 120 140

[°C

]

[min]

10 min

120 °C

100 °C

80 °C

25 °C

Right side

Aft 120 °C

25 °C

before after


Test

Test set-up: Vibration


• Experimental modal analysis set-up:

VISATON FRS8

Test procedure: sweep scan through multiple points pre-defined on the surface of the analyzed object. Input power spectral density coming from excitation source: loudspeaker or shaker.Equipment: • 3D Scanning Vibrometry System (PSV-500-3D), • loudspeaker (VISATON FRS8, with a linear frequency response up to 20000 Hz), • Shaker (MB Dynamics 50A modal exciter). The shaker can produce up to 225 N

peak force (when cooled with forced air) between DC and 4000 Hz. The shaker A solid-state power amplifier (MB Dynamics SL500VCF) with a frequency range between DC and 200Hz drove the exciter.

PSV-500-3D Scanning Vibrometer

MB Dynamics 50A modal exciter

Two different Excitation sources:


Test• Modal analysis (Free-Free)

Objective: Evaluate natural frequencies

Test article: Cold plate (#2) only, Free-Free cond.

Test procedure: simply supported CP on foam excited by loudspeaker

Equipment: PSV-500-3D Scanning Vibrometer,

Excitation source: loudspeaker VISATON FRS8

Cold plate #2


1st Mode 1522 Hz; 2nd Mode 1746 Hz; 3rd Mode 2358 Hz

1st Mode 1522 Hz 2nd Mode 1746 Hz


Test setup

Scanning vibrometer Loudspeaker

foam

foam

3rd Mode 2358 Hz

Test resultsClick for movie

Test

Cold plate #2


First freq. bending in longitudinal direction: 1522 Hz (no end blocks); second freq. bending transversal direction (1746 Hz)

• Modal analysis (Free-Free )(link)



Test• Modal analysis (Fixed-Fixed )

Objective: Evaluate natural frequencies CP+EB

Test article: Cold plate (#2)+ EB., Fixed-Fixed.

Test procedure: XX

Equipment: PSV-500-3D Scanning Vibrometer,

Excitation source: Shaker MB Dynamics 50A

Cold plate #2


Test setup

1st mode 803 Hz

2nd mode 1038 Hz

Fixed Fixed Shaker


3rd mode 1534 Hz

Click for movie

4th mode 2201 Hz

Test

Cold plate #2


• Modal analysis (Fixed-Fixed )


Analysis• Modal analysis:

Material, mesh and boundary conditions (BC):

• Shell elements.

• Mesh size 1mm

• Same stack-up Design 1

Finite element analysis:


Fixed-Fixed: Areas corresponding to End-blocks gluing have been fixed

A

A

A Ux, Uy, Uz =0

Materials:

Material/sub-laminate Thickness (mm) Or.(deg) Number

FGS-003 0.04 1

EX-1515/K13D2U 2K 0.107 90 1

EX-1515/K13D2U 2K 0.107 0 1

EX-1515/K13D2U 2K 0.107 90 1

FGS-003 0.04 1

Total 0.4

EX-1515/K13D2U 2K, 120gsm, 33% RC6

Lamina Properties (Koller & Springer)

E11 367.68 GPa

E22 6.35 GPa

E33 6.35 GPa

G12 5.76 GPa

G23 2.06 GPa

G13 2.06

v12 0.286

v23 0.538

v13 0.286

FGS-003

Lamina Properties

E 8.97 GPa

G 3.2 GPa

v 0.4 GPa

Material/sub-laminate Thickness (mm) Or.(deg) Number

FGS-003 0.0975 1

EX-1515/K13D2U 2K 0.107 0 15

FGS-003 0.0975 1

Total 1.9

Analysis• Free-Free: Results

Finite element analysis: modal analysis


Tuning of the FE Model to match Modal test results on free free configuration

228Hz 1541Hz 1699Hz

1709Hz 2179Hz 2376Hz

1522Hz*

1746Hz 2358Hz*

*Experimental**Effective mass ratio (%)

Analysis• Fixed-Fixed: Results



The modal shapes and frequencies are compatible with the test

1486Hz 2042Hz 2070Hz

2446Hz 2675Hz 2705Hz

1534Hz*

*Experimental

2567Hz*

2201Hz*

Y-Dir 32.1% *

**Effective mass ratio (%)

X-Dir 32.6% * X,Y,Z-Dir ~ 0% *

Y-Dir 31.5% * X- Dir 33.5% *Y-Dir ~ 7.44% *

(most in the ribs)(most in the ribs)

X-Rot 19.1% *

X-Rot 18.8% *

Y-Rot 27.8% *

Y-Rot 28.7% *

Z-Rot 41.2% *

Z-Rot 24.5% *

Back up


BACKUP

Back up



• Fixed-Fixed: mass contribution

Back up



• Fixed-Fixed: mass contribution (extended)

Back up

Masterbond glue for end blocks gluing


Back up


limadou hepd-02 tracker cold plate prototypes production ... · 17/03/2020 corrado gargiulo |...

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