1 IST development status  Seattle  Composite Design

2 IST development in Seattle  Problem on autoclave has been fixed end of April  First sector of 700 mm long under fabrication (?)  Next 4 longer sectors to follow (1 day estimated per sector, curing included!) from Colin: -Hi Franck, I have asked Bill Kuykendall to let you have the necessary information for Eric. Here in Seattle, as you know we have been having a great deal of trouble with our autoclave. We finally got it working last Friday and made a short section and used that to do a test joint. We will now go ahead and make the central 700 mm section of the IST prototype. Then check that out and go ahead with the other four sections. It only takes a day to lay-up and cure each piece, assuming that the autoclave continues to function. Our backup plan is to use a local, commercial outfit to cure the lay-ups. I will be at CERN from June 2 until June 17th and will attend the IBL meeting. Henry tells me that you have a very long surface table available to assemble the full length prototype. I hope to have the pieces at CERN by then and will be able to work on the assembly. I will bring our mandrel to use as an assembly tool. I will also need to make and bring along a few V-blocks to support the rest of the IST as it is assembled. I will need help with aligning the mandrel and the V-blocks on the table. The mandrel will be cantilevered from a simple support that is clamped to the table. For the final object we will need to use a heat blanket to cure the joints in view of the bake out thermal load that the IST will experience. This is probably not necessary for the prototype unless you think otherwise.  IST proto is to be assembled at CERN (5 sectors, using Seattle mandrel)  Need of a long table at CERN (Bldg180) and help to prepare things in- situ (clamping, V blocks,…by Mid June)  we need from them to understand the full assembly process! Step by step (any doc’s?) 700mm sector Joint part (under testing)

3 IST joint test Colin Daly, Bill Kuykendall Univ. of Washington 10 June 2011

4 Short section of 7-layer tube made with K13C/RS-3 pre- preg. One end (male) has 4 layers over the inner surface of a 50 mm long section. The other (female) end has 3 layers on the outer surface of a 50 mm long section.

5 Joint prior to gluing.

6 Finished joint. It was glued using a low viscosity epoxy while being held on the lay-up mandrel. The assembled tube is very stiff both axially and circumferentially. We will get some dimensions as quickly as possible but the tube fits perfectly on the precise mandrel and does not need any out of round deflection to get it on and off. The ID is, of course, a little larger (40 microns in theory), than the 85 mm diameter steel mandrel because of the differential contraction as it all cools down after curing.

7 IST Composite Design -First 2.4m long sector laid-up around the mandrel yesterday and put under vacuum -Today, curing is foreseen at 130°C - … Awaiting for de molding !! …and check out the resulting straightness Waiting for pictures! If everything OK, then 3 other sectors will be manufactured (less time needed since everything is validated…), and joined together See whether we need to add another short sector to get to the 7300mm for a Beam pipe container (see next talk)  Same technique to be used on the Dummy Beam pipe (  58mm, 0.8mm thick in M55J prepreg)… following right after dummy IST Fabrication!