FPIX Upgrade – Status of CO 2 Cooling Studies S.Grünendahl, FNAL for the FPIX Upgrade Mechanical Group H. Cheung, G. Derylo, S.G., S. Kwan, C.M. Lei, E. Voirin (Fermilab) K. Arndt, Q. Liu (Purdue) S.Grünendahl – CMS Pixel CO 2 Meeting1March 19, 2013

FPIX CO 2 Cooling Areas of Progress March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting2 Tests since previous meeting:: 2/12 1.4mm ID outer half-disk loop 2/14 1.4mm ID inner half-disk loop 2/21 1.6mm ID full length loop 2/27 Multi-blade disk w/TC 5022 pocket slots for blade-ring joint FEA study of through slot joint 3 Half Disks Port Cards and POH End Flange DC-DC converters Pipes and Cables CO2 cooling tubes and flex cables

Loop Tests Update Full length stainless steel tubing assemblies with dummy heat loads Measure temperatures vs. flow & pressure drop Initial finding: pressure drop larger than in simulation Adding concentric heat exchanger, to guarantee subcooled liquid, and fine-grained RTD placement to confirm transition to two-phase flow New studies: variations in tube diameter inner/outer half lengths configurations March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting3

Loop Setup March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting4 subcooler Fine grained RTD placement to locate onset of two-phase flow

1.6mm ID Full Loop Test March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting5

Loop Tests: Combined Results March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting6

Loop Tests: Combined Results II March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting7

Joao’s Calculations Outer loop, full heat load, lowest stable experimental mass flow (0.65 g/s) and 1.5 times l.s.e.m.f. (1.07 g/s) March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting8

Joao’s Calculation I March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting9

Joao’s Calculation II March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting10

Calculation vs. Experiment Lots of discussion and progress on understanding of difference simulation vs. experiment Many calculations by Joao (Thanks!) My conclusion: all except Delta P seem to agree difference maybe not all that surprising: Even (easier) single phase flow depends a lot on parameters like e.g. tube roughness that are hard to control March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting11 (From Eric & Joao)

Loop Test Conclusion Both parallel (with 1.4mm ID) and serial (with 1.6mm ID) are viable Decision will have to take into account complexity, material accounting and redundancy/failure tolerance considerations March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting12

Multi-blade Tests: TC 5022 in Pocket Joints Improved joint geometry control (dry fit to equalize radial play for all blades before assembly) March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting13 A1silicon 1 ctr A2silicon 2 ctr A3silicon 3 ctr A4Blade 1 ctr A5Blade 2 ctr A6Blade 3 ctr A7silicon 1 i A8silicon 2 i A9silicon 3 i A10silicon 1 o A11silicon 2 o A12silicon 3 o A13Blade 1 i A14Blade 2 i A15Blade 3 i A16Blade 1 o A17Blade 2 o A18Blade 3 o B1Ring i B2Ring i B3Ring i B4Ring o B5Ring o B6Ring o B7silicon 4 ctr B8Blade 4 ctr B9silicon 4 i B10Blade 4i B11Ring i B12silicon 4 o B13Blade 4o B14Ring o B18tubing mid B19tubing in B20tubing out ∆T=0. 3 ∆T=0.6 ∆T=- 0.3 ∆T=1. 0 ∆T=0. 6 ∆T=1. 0 ∆T=1.7 ∆T=2. 5 ∆T=0.2 ∆T=0. 3 ∆T=2.4 ∆T=1. 5 ∆T=2. 1 ∆T from CO2 to inner ring = ∆T=0. 2 ∆T= ∆T= ∆T=1. 1 ∆T=2. 0 ∆T from CO2 to outer ring = ∆T from CO2 to silicon center =

Ansys vs. Experiment March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting14 Good match using data sheet material properties and nominal dimensions (i.e. no fudge factors)

Conclusion TC 5022 pocket joint fully qualified Necessary joint QC depends on blade manufacturing tolerances; in any case doable, even if a bit labor intensive March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting15

Blade-Ring Joint FEA Studies Motivation: Through slot might have practical advantages for half-disk assembly March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting16 Maximum Silicon Temperature Radial Thermal Conductance (W/m^2/K) Axial Conductance Maximum Silicon Temperature Radial Thermal Resistance (cm^2*K/W) Axial Resistance Nominal joint parameters (material & thicknesses) Conclusion: radial heat transfer less important => might want to look at through slot again (Caveat: Studies without CF in joint area – repeat with CF)

Blade-Ring Joint FEA Studies II Better structural strength if carbon fiber cladding continues into joint pocket/slot Simulation looks ok March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting17

FPIX Cooling Layout ‘Decision Tree’ (from Kirk) March 19, 2013S.Grünendahl – CMS Pixel CO2 Meeting18 Left vs. Right HCs Symmetric (3 main lines) or Asymmetric (2+2 main lines) HD Inner + Outer in Series (1.6mm ID HD tubing) HD Inner + Outer in Parallel (1.4mm or 1.6mm ID HD tubing) inners + 3 outers Outer-inner-outer + Inner-outer-inner

η = 1.3 η = 1.6 η = 2.1 η = 2.5 2x8s Z loc. TBD shown 491mm from IP x8s Full geometry 19

η = 1.6 η = 2.1 η = 2.5 2x8s η = 1.6 η = 2.1 η = 2.5 2x8s Segmentation alternative #0 - Baseline - 1 st HD on one main line + 2 nd and 3 rd HDs in parallel on the other main line = two main cooling loops per Half-Cylinder 2 nd + 3 rd disks 1 st disks 3 hits 3.5 hits 3 hits 4 hits 3 hits 2 hits 20

η = 1.3 η = 1.6 η = 2.1 η = 2.5 2x8s η = 1.3 η = 1.6 η = 2.1 η = 2.5 2x8s Outer-inner- outer 4 hits 3 hits 2.5 hits Inner-outer- inner 3 hits 3.5 hits 2.5 hits Segmentation alternative #1 – two cooling loops per Half Cylinder (Total 4 cooling loops per end) 21

η = 1.6 η = 2.1 η = 2.5 2x8s η = 1.6 η = 2.1 η = 2.5 2x8s 22 Segmentation alternative #2 - All outers in parallel + all inners in parallel on two main cooling loops per Half Cylinder All Outers 4 hits 3.8 hits 1.5 hits All Inners 3 hits 2.5 hits 3.5 hits

η = 1.6 η = 2.1 η = 2.5 2x8s η = 1.6 η = 2.1 η = 2.5 2x8s Segmentation alternative #3 – three cooling loops per two Half- Cylinders (Total 3 cooling loops per end) 2 nd + 3 rd disks 1 st + 3 rd disks 3 hits 3.5 hits 3 hits 4 hits 3.5 hits 3 hits 23

η = 1.6 η = 2.1 η = 2.5 2x8s Segmentation alternative #3 – three cooling loops per two Half- Cylinders (cont.) (Total 3 cooling loops per end) 1 st + 2 nd disks 4 hits 3 hits 24

Summary  Loop tests show both parallel cooling loops with 1.4mm ID and serial loops with 1.6mm ID are viable solutions  Multi-blade tests: TC 5022 in pocket slot has been fully qualified for blade – ring joint  Further multi-blade assembly tests for carbonized and soldered joint are in preparation  Discussion on optimizing the FPIX cooling loop connection scheme is underway March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting25

Backup Slides Progress in related areas, from Purdue Delta p vs. flow for different diameters Tables for loop measurements March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting26

Designed custom front-end tools to pick-and-place HDI onto bare 2x8 bump-bonded modules. Semi-automated module assembly trials with prototype HDI will take place once these custom tools are fabricated. Work in progress to build a practical design and installation sequence for mounting, connecting, and cooling double-stacked port cards/POH in service (half) cylinders. Custom tools for pick-and-placing the HDI onto the 2x8 bump-bonded module (from Kirk):

Delta P vs. Flow March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting28

Loop Measurement Tables March 19, 2013S.Grünendahl – CMS Pixel CO2 Meeting29