theodore todorov pixel mechanics november 8th 2010 1 inner detector upgrade / ibl activities on...

Theodore TodorovPixel mechanics november 8th 20101

Inner detector upgrade / IBL

Activities on cooling circuits @ LAPP

LAPP team Jacky Ballansat, Patrick Baudin,Pierre-Yves David, Pierre Delebecque, Nicolas Massol,Thibaut

Rambure, Theodore Todorov,Tamer Yildizkaya

1. Specifications

2. Current R&D goals and program

3. Fittings R&D

4. Stainless steel cooling loop

5. EB welding and brazing

6. Bending

7. Pipes order

8. Qualification and quality assurance


Cooling services for IBL

2

Inlet connectors

Outlet connectors


Specifications (mainly for IBL)

Functionnal:

Maximum leak flow (He) : 10-5 mbar.l.s-1 @1 barPresure (bar):

Xo (minimise)

Radiation level : up to 1000 Mrad

Temperature : mean = -35 °C (maxi +40 °C ; mini -60 °C)

Pipes inner diameters : 0.8 to 3 mm

Pipe material : Titanium grade 2

Pipe thickness : 0.1 to 0.3 mm depending on ID

Available space for the fittings : less than F10 mm

Test Max design

service ultimate

service normal

CO2 150 100 70 20

C3F8 25 ?? 15 10

1 - Specifications


Connector positions for ID Upgrade

4

At end of stavesBoth SCT and Pixel

At PP1Both SCT and Pixel No manifolding in ID volumeManifold at PP1

Alternative for Pixel:• Patch panel with manifold at

end of pixel package• Small connectors between

staves and PPP• Larger connectors & pipes

between PPP and PP1


EB welding tests Bending tests

2 - Current R&D goals and program

Ti Pipe/fitting linkage

Dismountable connexion of 2 pipes Bending of Ti pipes

Ti Electron beam welding

Custom fittingIndustrial fitting

STÄUBLI ?

Brazing

Brazing tests

R&D program @ LAPP

Fitting tests


Until recently, we were focused on development of the Fitting, optimizing the geometry and the properties of the different surfaces.We performed test in order to validate the different designs, focusing on the minimal torque needed to achieve leak tightness.

Main developments

The last few months we have also worked on the "commissioning" of the fittings for routine use by other labs, for the cooling loop tests (stainless steel) and for the next stave prototypes (Ti).This involved studying the usable torque range, in order to deduce a recommended torque and the tooling.

2 - Current R&D goals and program


Base line design

Test @cold• 4 combinations 1 MaleTA6V /1 femaleTA6V tested -

OK • 1 MaleTA6V /1 female Stainless steel tested - OK

3 –Fittings R&D

Test @room temperature• 21 combinations 1 MaleTA6V /1 femaleTA6V tested -

OK • 6 MaleTA6V /1 female Stainless steel tested – OK• 2 tests to find ultimate torque : 8 N.m• Many more combinations tested in variations of the

design

Tightness optimisation• Define the optimal parameters (friction on the surfaces and

the threads• Tooling needed to control the torque


Spherical designToroid design

Misalignment influence (5°)

3 –Fittings R&D


Tests @ cold

3 –Fittings R&D – tests @cold


1. Hydraulic pressure test @ 150 bars @ room temp

2. He Leak test @20 bars @ room temp

3. Cooling from 20°C to -50°C

4. He Leak test @20 bars @ -50°C

5. Pressure test @ 150 bars @ -50°C

6. He Leak test @20 bars @ -50°C

7. Heating from -50°C to 20°C

General tests procedure @ cold

P

T

20

-50

20

150

2 3 4 5 6 71

H20 He

3 –Fittings R&D – tests @cold


Next steps

The base line solution for PP1 is defined

Increase the number of tested combinations with the base line designKeep on performing cold testsThermal cycling (100 cycles)Simple tests with liquid CO2 (bottle)Determine the limits of use for pressureStudy the tooling needed to control the torqueStudy the integration aspects

3 –Fittings R&D – next steps

Optimized design will be studied

OD reduced to 8mm (maybe 7 mm)Reduction of the amount of material


Cooling loop production and tests

3 –Stainless steel cooling loops

Goal Cooling loop made of stainless steel will be tests @ Nikhef

Production Pipes from NikhefFitting and bushings made @LAPPBrazing made by Bodycote -> new surface treatment made of graphiteProduction samples made of same components and brazed at the same time as the cooling lines tested @LAPP (QA procedure)Should be delivered on Week 46

Fitting tests Design developed for Ti -> need to be check for stainless steel


Stainless steel fitting

Test @cold• To be done

3 –Stainless steel cooling loops

Test @room temperature• 13 combinations 1 MaleTA6V /1 femaleTA6V tested - OK • 2 tests to find ultimate torque : 8 N.m ->no leak• Dismounting/mounting torque 4 N.m –No leak• Dismounting/mounting torque 2 N.m –leak flow few 10-7

Kept under 20 Bar He 2 hours : leak flow -> few 10-9 to few 10-8

Kept under 20 Bar He 17 hours : leak flow -> same evolution (He diffusion around the leak detector ?)

• 20 mounting/dismounting : OK


4 –EB welding and brazing

Status 30 samples brazed and 30 EB welded, changing the material and the cleaning

FinishedBrazed an EB samples were tested @RT ->OKCold tests on part of the brazed samples ->OK

In progressFinish the cold tests (mostly finished, OK) Perform thermal cyclingMetallographic analysis to be performed @CERN


Stainless steel cooling loops brazing• Temperature : > 1000 °C

• Material 60%cupper / 40% Gold

Issue : capillaries may be filled upID 0.8 mm

ID 2 mm

4 –EB welding and brazing


4 –EB welding and brazing-in situ brasing machine

GoalBrazing the pipes during integration

DeviceVacuum chamber + heater (induction, infra red ?)Experts from Bodycote + ….

LimitationsEffects on the environment ?Control of the brazing ?

!!

Brainstorming !!

Vacuum chamber

Heaters

theodore todorov pixel mechanics november 8th 2010 1 inner detector upgrade / ibl activities on...

Documents

fittings rd slide

torque slide

program slide

pp1 slide

fittings rd test

lapp fitting tests

current rd goals

eb welding tests