3D Printing Developments Francois-Xavier Nuiry Giulia Romagnoli Tobias Polzin Edouard Grenier Boley Romain Gerard EN-MME-FW With the support of TE-VSC

3D Printing Technology Validation 3D printing design is innovative for a dump R&D necessary to validate the technology before installing it inside accelerator Design challenges: Material porosity Wall thickness between cooling channels and vacuum Mechanical fatigue Thermal fatigue Water erosion Particle damage fatigue Test pieces produced to validate the design 12/10/2016 PS Internal Dump Core Review

3D Printing Part Used @ CERN Interest towards metal 3D printing is been growing at CERN Parts already installed in the accelerators/detectors and several tests are going on… In particular, regarding 3D printing in Ti6Al4V there are: A cooling circuit installed in the core of the CMS experiment Several forks of rotary beam wire scanners installed in the SPS Validation tests going on inside the VSC group X-band applications (several tests going on…) Cooling loops of the CMS PLT detector SPS Fork of rotary beam wire scanner Ti6Al4V 3D printed Installed since 2014 Radiation environment 1.7 m from IP 60 mm from beam pipe Under water pressure Ti6Al4V 3D printed Fast movement /Fatigue Radiation environment Installed in Jan 2015 Under vacuum (10-9 mbar) 100 mm Proved non-contamination of powders Outgassing rate ~ 6x10-9 mbar l s-1cm-2, H20 eq. after 10 hours pumping Wall thickness 0.4 mm He tight Pressure test @ 15 bar * Ray Veness presentation @ https://indico.cern.ch/event/333735/ * EDMS # 1335390 * Contact: Robert Loos EP-DT-CO 12/10/2016 PS Internal Dump Core Review

3D Printing for X-Band Applications X-band prototypes for high power test: Integration with water cooling system Application under vacuum Specimens in Ti6Al4V for material characterization: Vacuum: leak tightness OK ( 10-4 mbar inside the piece and He outside) Mechanical strength and metallurgy Shape accuracy and microtomography Outgassing tests Operation with cooling and vacuum: Water ~ 25° C and 2/3 bar VACUUM 2e-9mbar Wall thickness 1.2mm * Contact: Alexej Grudiev BE-RF-LRF 12/10/2016 PS Internal Dump Core Review

Metallographic and Mechanical Tests * Test done by MME EDMS # 1343646 3T RPD AM company INP Grenoble Institute of Technology Concept Laser 3D printing machines TENSILE TESTS Company Emod (GPa) Rp0.2 (MPa) A % UTS (MPa) 3T RPD 112 ± 1 1097 ± 8 2 ± 0 1139.8 ± 3.0 INP 51 ± 0 830 ± 36 11 ± 2 904.8 ± 20.4 CL 108 ± 1 825 ± 11 12 ± 3 893.4 ± 10.7 Laser Sintering process Electron Beam Melting process Laser Sintering process Conclusions: Porosity is better with LS than EBM Metallography for INP and 3T is similar to casted alloy Tensile tests: CL similar to annealed alloy 3T similar to solution treated INP similar properties to the annealed alloy but low elastic module due to high porosity 12/10/2016 PS Internal Dump Core Review

Metallographic and Mechanical Tests * Test done by MME EDMS # 1343646 3T RPD INP CL TENSILE TESTS Company Emod (GPa) Rp0.2 (MPa) A % UTS (MPa) 3T RPD 112 ± 1 1097 ± 8 2 ± 0 1139.8 ± 3.0 INP 51 ± 0 830 ± 36 11 ± 2 904.8 ± 20.4 CL 108 ± 1 825 ± 11 12 ± 3 893.4 ± 10.7 LS process EBM process LS process Conclusions: Porosity is better with LS than EBM Metallography for INP and 3T is similar to casted alloy Tensile tests: CL similar to annealed alloy 3T similar to solution treated INP similar properties to the annealed alloy but low elastic module due to high porosity LS selected as technology process 12/10/2016 PS Internal Dump Core Review

PS Internal Dump Tests Pieces Produced by 3T http://www.3trpd.co.uk/ 2 test pieces in Ti6Al4V with Direct Metal Laser Sintering (DMLS) technology 3D printed TEST parts to validate the design Brazing test Electro Beam Welding Test Leak tightness test with He Pressure tests with water Vacuum tests Metallurgy test on the assembly Tomography check Printing direction 100 mm 3D printed specimens for: Tensile tests EBW tests Outgassing Leak tightness * in collaboration with EN-MME thanks to Romain Gerard 12/10/2016 PS Internal Dump Core Review

PS Dump Test Pieces Planned Tests FIRST foreseen tests: Machine internal diameter Ti housing connection to the blocks: brazing test Machine welding key for EBW test EBW test to weld the 2 dump parts bout a bout Welding 2 parts due to limits of length in 3D printing First brazing tests on going… Brazing procedure validation in the following weeks! CDD numbers: PS_TDIL_0009 / PS_TDIL_0010 Tests in collaboration with EN-MME 12/10/2016 PS Internal Dump Core Review

PS Internal Dump Core Review Pieces for EBW Tests Cylinders for EBW test Plates for EBW test EBW test on going… Procedure validation in the following weeks! CDF numbers: PS_TDIL_0011 PS_TDIL_0014 Tests in collaboration with EN-MME-FW 12/10/2016 PS Internal Dump Core Review

VSC Group Leak Tightness Tests Leak tightness tests with membranes VACUUM He INITIAL http://www.prodways.com/fr/initial/ SLM (EOS machine) 3 different thicknesses (TH) in SS, Ti and Al: 0.25 mm 0.5 mm 0.75 mm Ti not leak tight in the 3 thicknesses! 12/10/2016 PS Internal Dump Core Review

Membranes Specimens for Leak Tests TEST done with sensor sensibility of 1E-10 mbar l/s He during 10 seconds Thickness Orientation RESULT 0.25 mm XY leak Z étanche 45° 0.5 mm 0.75 mm 1 mm 1.5 mm 2 mm 2.5 mm Problems to manufacture thin membrane (0.25) Tests in collaboration with TE-VSC thanks to Ludovic Mourier 12/10/2016 PS Internal Dump Core Review

Outgassing and Tensile Tests OUTGASSING TEST still on going… Cleaning:  Procédure de dégraissage avec machine aux solvants MEG 12 specimens not HIP (foreseen test on HIP samples) Chamber size: Ø 4 cm x 27 cm room temperature 20°C Specimens total surface: 246 cm2 Total outgassing: 2.2E-12 mbar l/s BG outgassing: 1.3E-12 mbar l/s Specific outgassing: 3.6E-15 mbar l s-1 cm-2 Tests in collaboration with TE-VSC thanks to Marco Morrone TENSILE TESTS foreseen - 24 tensile tests specimens for outgassing tests and tensile tests 12 with HIP treatment 12 without HIP Metrology Ra measures done to study the influence of Ra on mechanical properties Design conform to ASTM E8 Tests in collaboration with EN-MME-MM 12/10/2016 PS Internal Dump Core Review

PS Internal Dump Core Review Conclusions 3D printing in Ti is a very promising technology STI is taking advantage of this project to “innovate” for challenging materials for BIDs. Collaborating with VSC in order to have clear acceptance procedures for 3D printed systems Results obtained: He leak tightness with wall thickness ≥ 0.5 mm Low outgassing levels Tensile strength comparable with annealed alloy Further tests are necessary before validate the technology for beam intercepting devices Porosity controls Mechanical fatigue Thermal fatigue Particle damage fatigue Materials response to high long term radiation damage Water erosion Testing of a prototype target in HiRadMat in early 2018 12/10/2016 PS Internal Dump Core Review

PS Internal Dump Core Review Thank you! 12/10/2016 PS Internal Dump Core Review

Tensile Tests Foreseen 12 with HIP treatment 12 without HIP 24 tensile tests specimens for outgassing tests and tensile tests Design conform to ASTM E8 Identification number written on every specimen Tests in collaboration with EN-MME-MM 12/10/2016 PS Internal Dump Core Review

PS Internal Dump Core Review Metrology Results - Ra Ra measures on the dump pieces Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Piece Zone Orientation Ra (en µm) Rz (en µm) 1 Zone 1 90° 9.26 55.35 Zone 2 11.63 72.21 Zone 3 11.60 74.11 Zone 4 + 45° 12.64 71.53 Zone 5 - 45° 17.75 83.96 2 12.43 72.28 9.44 60.95 9.70 58.66 22.55 101.82 21.29 109.14 Rugosimeter MITUTOYO SJ 301 Palpeur conique 60° pointe diamant (rayon de points : 2µm) Longueur de base = 2.5 mm Longueur d’évaluation = 12.5 mm Estimation de l’incertitude de mesurage : 10 % de la valeur du paramètre Tests done by EN-MME-MM – EDMS numbers: J3034156 - J3034882 12/10/2016 PS Internal Dump Core Review