Cooling loops for prototype Staves ATLAS Upgrade WP4 meeting Lancaster University 4th Dec 2012 Cooling loops for prototype Staves Update on cooling pipes progress Confirmation of design of loop Discussion on design developments of loops for future staves Richard French - The University of Sheffield Martin Gibson, John Matheson, John Hill, John Noviss – RAL Ian Mercer - Lancaster

Tube stock availability   Production Sample Material OD mm ID mm Wall um length m  Stock Due Offcut Qty P/S/O CP2 Ti 3.175 2.775 200 2.2m 22 P 2.500 2.365 140 3.1m 1 S 2.275 2.025 125 3.0m 2 50 1.995 18 1.775 1.525 8 1.200 0.400 6 0.900 150 0.6m 4 17 1.000 0.450 275 0.360 270 0.800 0.500 0.750 0.490 130 0.670 0.405 132.5 0.595 0.330 316L SS 220 5.0m 14 1.8m 5 O 2.7m 750 2.0m 2.000 53 Aluminium 360 32 660 74 2.480 69 4.760 340 2.5m Titanium capillaries and exhaust tubing due to be delivered 3rd December 2012. 0.80 x 0.50 & 1.20 x 0.90 = capillary development requiring normal tolerances with uniform dimensions. Old Stave 2.275 x 0.125 = (2.00+0.05/-0.00mm Bore x 0.125+/-0.025mm Wall) New size 2.275 x 0.140 giving a bore 0.03mm smaller 1.97+0.05/-0mm Easier to weld – more robust. In order to get 3 Metre+/-10mm Lengths, amended all the 50 Metre quantities to 51 Metres (i.e. 17 Lengths x 3M). Trying 2.5mm OD x 140um wall; Standard (ish) OD & bombproof. Prototype capillary tubing fresh from the mill has now reduced wall to 0.750mm OD x 0.490mm ID x 0.1300mm Wall. 0.670mm OD x 0.405mm ID x 0.1325mm Wall. 0.595mm OD x 0.330mm ID x 0.1325mm Wall.

Vacuum Brazing 316L-CP2 Ti Problems all the way First – Silver plating on nuts contaminated brazed joint The VCR nut threads are silver plated to prevent gauling during assembly. This silver is reflowed during the furnace cycle = remove. Latest – Cu plating is proving difficult to be uniformly coated down the narrow bore of the fitting If proves impossible I will reduce the depth of the mechanical joint to allow better penetration of the Cu fitting. Summary – it is still a Cu plating problem with the 316L fitting – the braze process works on larger items. 1/8” Ti to VCR 2.275mm OD Ti to VCR 1/8” Ti to VCR NEW REFLOWED

Confirmation of design Confirmation of design? Stave ‘09, Stave 250, Stave130 SMC, EoS arrrghghgh……

EOS – how does this shape up? New z = 1.3m Stave end John Noviss What is length tube sticking out from stave end? Universal decision for 250. EOS – how does this shape up?

Image of z=1.3 Stave end How much tube length is used in total up to this point?

Specifications Stave name Raw tube Bend radii EoS Y/N Z=0 radii Comment Stave 250 2.275mm; 1/8” Ti. 1/8” 316L N Majority made in 316L SS. CP2 Ti on shelf in 1.8” OD & 2.275mm OD Stavelet 250 None spare Stave 130 2.275mm Ti None made Stavelet 130 Pressure drop 316L & CP2 Ti Various parts made based on Stave 250, with and without SMC, 1.2 & 1.6m stave PIXEL Disc 2.275mm OD CP2 Ti 1x half disc rough prototype made Encapsulated joint 1/8” CP2 Ti In work – one item to make based around?

From past planning Assuming we have minimal decisions made so rather vague or exceptionally obvious Stave, Stavelet cooling circuits Re-stock of cooling circuits and stavelet circuits. Include pressure testing > DATABASE entry. Re-stocking of tube material and bending trials on capillary tubing Pressure drop measurements – Components part produced – design finalisation required CO2 plant booking Feb13 see Richard Bates’ presentation later. TIG Orbital Welding. Reprogramming M200 and using grounding system from new system = part done Gas purge over long distance and multiple manifold measurements/effects on weld quality = started Measurements of electrode tip angle – arc gap and power v weld quality = 2013 Finalised electrode – seeking mass production or tooling to make in house. = 2013 Continuing to refine Swagelok weld head for heat sinking and improved tube alignment. = on going Bring online the InterPulse system and test on 2.275mm OD 125um wall CP2 Ti. = part done / on going / slow Laser welding Hopefully see Ian Mercer’s presentation for an update from Mike.. Material reduction Changing bulbous sleeve joint to butt weld on 125um tube with tooling from PIPE ltd. = Slow as small sizes Reducing mass in capillary tube wall – production limits. = Done Fittings Vac brazed stubs full statistical trial. = VERY SLOW and still waiting for test pieces CP2 ti fittings – material sourced from Sandvik. Need to check cost out v custom fitting from Swagelok or Fti plus the effort put in at QMUL. = Material rubbish – won’t weld. Re-manufacture of 6LV VCR thin wall fittings as run out. = Done Thermal shock etc in the pipe line at some point – hardware almost completed at RAL. = ¾ done Burst testing of circuits to see where calculated headroom is v actual – mass reduction maybe. = ISIS contacted ????