US CMS Silicon Tracker Project Joe Incandela University of California Santa Barbara US CMS Silicon Tracker Project Manager DOE/NSF Review of CMS Detector Project Fermilab May 20, 2004

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 2 Tracking Requirements Efficient & robust Fine granularity to resolve nearby tracks Fast response time to resolve bunch crossings Radiation resistant devices for 10y of LHC operation Reconstruct high P T tracks and jets ~1-2% P T resolution at ~ 100 GeV Tagging b, c and  jets Asymptotic impact parameter  d ~ 20  m The Goal – to be ready for first physics

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 3 US Responsibilities 5.4 m 2.4 m Outer Barrel (TOB) ~105 m 2 NEW:End Caps (TEC) 50% Modules for Rings 5 and 6 and hybrid processing for Rings 2,5,6

Pisa ROD INTEGRATION AachenKarlsruheStrasbourgZurichWien PETALS INTEGRATION Aachen BrusselsKarlsruhe Louvain LyonStrasbourg Brussels Wien Lyon TEC Assembly CERN Frames: Brussels Sensors: factories Hybrids: Strasbourg Pitch adapter: Brussels Hybrid: CF carrier TK ASSEMBLY CERN Louvain Strasbourg PerugiaWien Bari Perugia BariFirenzeTorinoPisa Padova TIB-TID INTEGRATION FNAL UCSB TOB Assembly TIB-TID Assembly CERN/USA PisaAachenKarlsruhe.--> Lyon Karlsruhe Sensor QAC Module assembly Bonding & testing Sub-assemblies FNAL Integration into mechanics Pisa RU FNAL UCSB Catania UCSB US in the tracker US carries almost half of the production load

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 5 North American Group Fermilab (FNAL) M. Demarteau, A. Ronzhin, K. Sogut, L. Spiegel, S. Tkaczyk University of California, Riverside (UCR) P. Gartung, G. Hanson, G. Pasztor University of California, Santa Barbara (UCSB) A. Affolder, S. Burke, C.Campagnari, D. Hale, (C. Hill), J.Incandela, S. Kyre, J. Lamb, S. Stromberg, (D. Stuart), R. Taylor, D. White University of Illinois, Chicago (UIC) E. Chabalina, C. Gerber, T. Ten University of Kansas (KU) P. Baringer, A. Bean, L. Christofek, D. Coppage University of Rochester (UR) R.Demina, R. Eusebi, E. Groves, E. Halkiadakis, A. Hocker, S.Korjenevski, P. Tipton Mexican Consortium (MEX) Cinvestav: H. Castilla, R.Perez, A. Sanchez Puebla: E. Medel, H. Salazar San Luis Potosi: A. Morelos Brown University (BU) R. Hooper, G. Landsberg, H. Nguyen, C. Nguyen Kansas State University (KSU):T.Bolton, W.Kahl, R.Sidwell, N.Stanton (Now working on Pixels)

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 6 Outer Barrel Modules 4128 Axial (Installed) 1080 Stereo (“ “) Rods 508 Single-sided (“ “) 180 Double-sided (“ “) US Tasks All hybrid bonding & test All Module assembly & test All Rod assembly & test Joint Responsibilities with CERN Installation & Commissioning Maintenance and Operation ~20 cm Modules Built & Tested in US

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 7 Rods & Wheels 0.9 m 1.2 m

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 8 End Cap Construction Central European Consortium requested US help With consent of US CMS and DOE, we agreed to produce up to 2000 R5 and R6 modules After 10 weeks UCSB successfully built the R6 module seen above. UCSB has built 27 R6 and 3 R5 modules to date Several hundred TEC hybrids in storage Expect Hamamatsu silicon in July for building TEC First TEC Module Built at UCSB

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 9 Summary (1) Problems continued to plague components this year US contributions have been critical US played major role in finding and fixing a series of flaws In some cases they would have been fatal Problems for module components have been addressed Frames and hybrids: Yields and rates are high and rising Sensors US identified CM Noise and other problems with STM sensors US advocated shifting order to HPK: Funded procurement of masks Pressed for order to be placed with HPK in February – beyond which we would have delayed HPK production CMS is reviewing STM now Either STM quality reaches adequately high standards or the remainder of the order will be shifted to HPK Upshot: we’ll have very high delivery rates by July

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 10 Summary (2) The schedule has slipped Lost 6-8 months in FY04 Our response In parallel with our work to find and resolve all component problems we have improved our production capacity Upgraded US production lines for much higher capacity Developed new and better methods More and better tooling and hardware Better software and Quality Control (QC) US production lines demonstrated more than 100% increases CDF or D0 Run 2 silicon detectors ~ 750k channels each: We could produce 750k channels in 6 weeks …

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 11 Outline Remainder of talk Module components: Problems, fixes, present status Rod components: status Actions taken by the US group Production improvements Added safeguards Failure analyses and spares procurement Additional groups, manpower, expertise Current Schedule Cost Performance Remaining concerns

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 12 Hybrid Problems Serious problems were uncovered by US and CERN 1.Flex cable fragility (US) 2.Weak wirebonds (CERN) 3.Power via opens (US) 4.Overlapped bonds (CERN) Discovered early Solved Quickly Excellent communication between US and Europe Great relationships with vendors Problems typically have been diagnosed, understood, and removed in 1-4 weeks! These could have been fatal

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 13 Sensor Production Thin Sensors (320  m) 6273 of 6877 (91%) delivered Yield > 99% at CMS QC Thick Sensors (500  m) 7000 ordered from HPK June Deliveries - all sensor types Some already received Large deliveries start in July HPK has capacity to make all CMS sensors on schedule HPK schedule has slipped less than 10 days in 4 months Thick Sensors (500  m) Initially ~87% yield at CMS QC Required full testing of all sensors  NOT POSSIBLE Major efforts by the CMS tracker and STM  yield at CMS QC increased to ~ 98% Still some concerns Final sensors currently being tested by CMS 500 delivered US CMS will build 200 modules from these sensors starting in June as part of the qualification study Hamamatsu Photonics (HPK)SGS Thomson (STM)

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela CMN Noise Issue Example: Sensors and Channels causing the problem 203 at 70V 251 at 130V CMN problem first reported by US in July Understood to be a pt. discharge/breakdown effect

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 15 Correlation of CMN with  I Increased leakage current over time even if left “on the shelf”. High correlation with large common mode noise (CMN)

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 16 First IV in standard Vienna qtc setup: sensor outside specifications (20µA) Vacuum switched off: Sensor perfect 0.5 µA Vacuum switched on again: Sensor again bad (20µA) Sensor No visible defects 2. Vacuum - effect without vacuum with vacuum

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 17 Sensors with odd noise structure: Good sensor 3. Time structure in leakage current

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 18 Deliveries as of mid February show a new class of sensors: All sensors have currents >1.5 µA : all grade B (have to be fully tested 100%) IV curve in most cases flat, are these sensors good? 4. Processing changes

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 19 Module Components Summary We do not have direct control but in the past year we have exerted a major positive influence. Problems with components, many of which were found in the US, led to delays of varying lengths Module breakage in transport → 2 months Hybrid Cable problem → +3 months ST Sensor issues → +5 months Hybrid via problem (found April 04) → no added delay ST sensors are the remaining concern Shifted order of 7000 (out of thick sensors) to HPK Re-qualifying STM final process now with decision in July Timing such that we can shift all production to HPK without impact on schedule if STM fails qualification

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 20 Sensor Strategy 7000 thick sensors have been ordered from HPK This was a major achievement in which the US was very active HPK must know by July/August if we want to increase this order in order to maintain CMS production without interruption. This will depend upon whether STM is qualified or not Requalification of STM Produce 1000 sensors with final processing by End of May CMS to determine if these sensors are acceptable IV,CV with vacuum - Full strip test - Long term test for 72 hours - Proton irradiation of sensors and test structures Module construction in the US Studied for sensor related defects not usually detected in sensor probing, e.g. CMN, unstable current, irradiation of modules, etc. If acceptance rate <98% order shifts 100% HPK This plan was presented to STM on March 31 st

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 21 Hybrids Progress Yield is stabilizing above 90%

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 22 Rods Bare rod assembly, cabling at CERN Modules mounted and full rods tested at FNAL, UCSB 6 (12) Modules per single (double) sided rod 760 rods to be produced 4 per rod

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 23 Rods Component issues resolved OptoHybrids Large quantities already shipped directly to CERN Frames 100’s delivered CCU modules were an issue last month. Not any longer Company now able to run CMS testing equipment Production of quality parts underway – first deliveries made Mounting/cabling at CERN is underway Can reach production rate of 50 rods/month US could conceivably help here if necessary One issue with potential damage in shipping Several good solutions under consideration

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 24 US Productivity Enhancements Gantry (robotic) module assembly Redesigned: more robust, flexible, easily maintained Surveying and QA Automated use of independent system (OGP) More efficient, accurate, fail-safe Module Wirebonding Fully automated wirebonding Faster and more reliable bonding Negligible damage or rework Taken together: Major increase in US capabilities Higher quality

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 25 Module Mechanical Precision Specifications are stringent  x between sensors the most critical quantity 97% modules in specs Results from many modules allow us to applying 2 nd order corrections Tune each position of each production plate All new modules are well within specifications  x(Frame-Sensor) (  m)  x(Sensor-Sensor) (  m)  (Frame-Sensor) (mdeg)  (Sensor-Sensor) (mdeg)

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 26 Bonding Centers TIB/TID Modules Bari,Catania, Firenze, Padova, Pisa, Torino TEC Modules Aachen, Hamburg, Karlsruhe, Strasbourg, Wien, Zurich, UCSB TOB Modules FNAL, UCSB UCSB and FNAL can keep pace with 15/d easily Bonded TOB module

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 27 Testing & QA Gantry makes modules Wirebond Bonded module test Assemble/test rods Rod burn-in Thermal cycle module Final pinhole test Quick test unbonded moduleThermal/quick test hybrid

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 28 Hybrid & Module Electrical Testing Testing occurs at each stage of production Critical for monitoring potential defects Specification: < 2% faulty channels per module Module testing has matured significantly Optimum (smallest/fastest) set of tests defined Excellent fault finding: > 99% faults found & correctly identified >90% of time < 0.1% of good channels flagged as faulty Standardization Easy comparison of results at different sites

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 29 Module Fault Finding Noisy 1 sensor open 2 sensor open Pinholes Bad Channel Flags Noise Measurement Pulse Height Measurement (Using Calibration Pulse) Bad Channel Flags Shorts Pinhole Opens

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 30 Module Quality Our goal is less than 1% faulty channels per module Results: 0.55% Faulty Channels Per Module Production introduced faults less than 0.1% A large number of modules have been produced with industrial methods and yet an unprecedented low rate of faulty channels

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 31 Rod Assembly, Test, Transport US contributions Designed and built module installation tools Built single rod test stands Designed and built and multi- rod burn-in stands Leading in the definition of tests and test methods Transportation Production Will build and test ~350 rods (+10% spares) at each site

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 32 US Substructure Integration Shells, petals, rods underway ~10 rods and ~2 petals have had modules mounted and tested at final assembly sites We do not build petals in the US but we have been supplying TEC modules used in Petal integration System tests are helping to finalize components and procedures Petals  improved cooling Rods & Petals have both modified grounding and shielding schemes  reduced noise

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 33 Substructures Beam Tests May 2003 Bunched 25 ns muons and pions Test subsystem integration TIB Layer 3 shell (6 modules) TEC petal (10 modules) TOB Rod (6 modules) Detector performance as expected and needed May 2004 Larger system integration Multiple rods, petals, shells Tracking tests Beam Direction

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 34 Rod Testing and Transport Rochester Long-term testing box: - 8 rods simultaneous operation - Thermal cycle 72 hours - All hardware in place - Finalizing multi-rod software Transport boxes: - Carefully engineered - Studied/Tested at commercial testing facility

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 35 Current Tracker Schedule

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 36 US Module Production (as determined by A. Cattai, J. Incandela, S. Schael) This is our current module production schedule: USA module final production TOB modules: Early June 2004 to May 2005 TEC modules: Late June 2004 to mid-April 2005 Paced by sensors & hybrids Currently it appears they will arrive simultaneously

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 37 Other Considerations Rods are expected to keep pace with module assembly Schedule for integration of rods on wheels has slipped US involvement in I&C was scheduled for second half of FY04. Now expect no major US involvement before second half of FY05 Most system integration will likely occur in FY06 We analyzed all systems for sources of downtime in production Stocked critical spares of fabrication tooling and equipment Cross-training fabrication personnel to maintain depth at each station Developed additional satellite hybrid processing capacity in Mexico Setting up specialized testing and diagnostics facility at UC Riverside Particularly important to remove this work from the production lines where it could be a distraction…

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 38 Cost Performance Contingency is being used Held off >1.5y before building labor force to full production levels Delays will lead to additional labor costs ~ 500k$ Upgraded Production capacity to provide schedule support Equipment, tooling additional labor costs ~ 550k$ Strongly advocated a quick startup of HPK production Purchase of HPK masks ~450k$

DOE/NSF Review - UCSB CMS Silicon Tracker - Fermilab - May 20, J. Incandela 39 Summary The tracker is one of the main strengths of CMS US is making critical contributions Additional costs have or will been incurred ~ 1.4M$ We’re now on more solid ground Increased US capacity from 15 modules per day to > 30 Rod assembly to keep pace with module assembly Detailed understanding of our components, and vendor processes All fundamental problems have been remedied or are being addressed Consequence for schedule: Final assembly of the wheels at CERN slips into FY06.