CMS Week, CERN, Mar Mar 2004CMS Week - Module ProductionSalvatore Costa - Catania Report on Module Bonding Salvatore Costa Università di Catania and INFN – Sezione di Catania

18 Mar 2004CMS Week - Module Production2 Salvatore Costa - Catania Outline 1.Global info on production bonding of the Modules 2.Global review of Module bonding quality indicators 3.Short summaries on specific topics discussed at the WG Meeting

CMS Week, CERN, Mar Mar 2004CMS Week - Module ProductionSalvatore Costa - Catania Global info on production bonding review of Module bonding quality

18 Mar 2004CMS Week - Module Production4 Salvatore Costa - Catania Production rate In all centers which have received modules (mainly IT & US) production bonding has started in earnest. All involved centers say they are currently limited by delivery of modules, not by their bonding capacity

18 Mar 2004CMS Week - Module Production5 Salvatore Costa - Catania Production Totals ZURICH after Hyb prod resumed with stiffener added to kapton cable 61 (180 TOB 27 TEC) 25+2

18 Mar 2004CMS Week - Module Production6 Salvatore Costa - Catania Center Summaries # Modules bonded & Repaired failures during bonding [Only Modules bonded after 01Dec2003] [Values in () are at time of last Mtg)] center# Modules /Module Bari64 (26)1.3 (0.5) Catania25 (11)12.6 (7.6) Fermilab79 (7) 0.7 (0.9) Firenze54 (29)2.3 (1.0) Padova55 (8)0.4 (3.6) Pisa140 (87)0.2 (0.4) Santa-Barbara207 (164)2.1 (1.7) Torino61 (18)0.0 (0.0) Vienna2 (0)0.0 (-) Zurich27 (4)0.0 (0.0) LOWER LIMIT!

18 Mar 2004CMS Week - Module Production7 Salvatore Costa - Catania Module Pull Tests Performed # Modules pull tested, separately per bond type after 01Dec2003 (at time of last Mtg) Results in DB from 10 Centers out of 14 (up from 9 at last Mtg) CenterPA TAPA-SenSen-Sen Bari56 (24)58 (24) n/a Catania25 (11) n/a Firenze1 (1) 0 (0) n/a Padova0 (0) 33 (0) n/a Pisa1 (1) 19 (18) n/a Torino19 (19) n/a Fermilab49 (7)7 (7)4 (0) Santa-Barbara36 (20) 35 (20) Strasbourg0 (0)16 (0) Zurich0 (0) 30 (4) n/a

18 Mar 2004CMS Week - Module Production8 Salvatore Costa - Catania Module Pull Test Results Summary BA CT PD PI TO FL FL SB SB ST ST ZH (irr#) (1n) ss ss ss

18 Mar 2004CMS Week - Module Production9 Salvatore Costa - Catania Module Quality  Bonding Summarizing from individual center reports … Overall, the fraction of modules that may be declared “bad” or “faulty” after (but not necessarily because of) bonding is very small: 6 currently known to me over ~650 (~1%). Virtually in all cases, however, this seems to be due to operator mistake or mishandling rather than to the bonding process itself. Mishandling may have occurred during bonding or at other times. After ~650 modules we can say that Bonding does not seem to be After ~650 modules we can say that Bonding does not seem to be a critical operation for the safety and the quality of the tracker Faults In detail Faults In detail: 1 module w/ unbondable PA because of a foreign liquid poured on it 1 module w/ APV-PA bonds crushed by bonding operator  shorts 4 modules draw high current and show visible scratches (in 1 case scratches predated bonding, in 3 stiil investigating) Less severe accidents/failures (lead to less than 2% bad strips) 2 modules have had a few bonds pulled for shorts and pinholes caused by inexperienced operator. 1 module ~100 bonds failed because of wrong parameter file, then were successfully redone 1 module ~100 bonds failed because of wrong reference file, then were successfully redone Few more accidental crushing of APV-PA bonds reported but no shorts have results in these cases. In general, we should be more careful in handling the modules. However, having to handle pieces, a few accidents serious enough to lead to modules rejection are to be expected.

CMS Week, CERN, Mar Mar 2004CMS Week - Module ProductionSalvatore Costa - Catania Selected highlights from the Bonding WG Meeting of 16 Mar 2004

18 Mar 2004CMS Week - Module Production11 Salvatore Costa - Catania News Mexico CityNew center: Mexico City –Effective clone of UC Santa Barbara –Will help with Hybrid bonding and testing

18 Mar 2004CMS Week - Module Production12 Salvatore Costa - Catania DB Web I/F v. 4.0 Released 14 Mar Major changes: 1.Automatic upload to TrackerDB of the XML files generated by the I/F 2.Improved input info download from TrackerDB: 1.Contacts backup host if main host is down at Lyon 2.Times out if answer takes more than 60 sec 3.Informs if connection failure or timeout.  Will be applied to ModProd DB Browser too 3.New skip rule (decided 2 Meetings ago, in agreement with Sensor Group) to produce the list of Sensor strips to skip. 4.Failsafe Sensor data search in DB to get bad IDIEL and CAC info: 1.it looks first for 'reference' data, 2.then for the most-recent non- 'reference‘ data, 3.finally suggests to bond all strips only if no data whatsoever are found for a given Sensor. 5.More changes concern details of forms filling

18 Mar 2004CMS Week - Module Production13 Salvatore Costa - Catania The 2 Bonding WG reference docs have reached maturity and now are “final” versions 1.Module Bonding Procedure  cms.ct.infn.it/bonding/bondproc.htm 2.Module Bonding Specs  cms.ct.infn.it/bonding/bondspec.htm  No more missing/not yet available info  But these documents are not frozen, info and data will be updated as need arises or growing experience suggests. WG Official Documents

18 Mar 2004CMS Week - Module Production14 Salvatore Costa - Catania TEC ceramic stiffener All centers involved had to modify bonding jigs. Details of the mods done at each center were given. [These are center- specific because each center specializes in bonding modules of certain EC rings] In general no major problems for bonding that could arise from the addition of the stiffener were reported Vienna said bonding with stiffener was as easy as before Strasbourg said they now apply vacuum on the stiffener now, not on the sensor, to hold the module steady during bonding Karlsruhe reported problem with vacuum because of excess glue under stiffener [Modules glued by hand] – Hopefully problem will go away when Module assembled with Gantry.

18 Mar 2004CMS Week - Module Production15 Salvatore Costa - Catania PA-Sen Bonds in TIB L1&2 1 st series (inner row) – loop height 200 micron Bond for pull test [every 25 of 1 st series (inner), repair as the red ones 2 nd series (external) [after all repairs on 1st series] – loop height 300 micron

18 Mar 2004CMS Week - Module Production16 Salvatore Costa - Catania PA-Sen Bonds in TIB L1&2 Courtesy of L.Demaria and F.Dumitrache, Torino

18 Mar 2004CMS Week - Module Production17 Salvatore Costa - Catania Hybrids with ‘weak’ control bonds This concerns two batches of Hybrids that are good enough not to be rejected but not of the usually good quality. Marked by blue labels on box and hybrid cable Alan conveyed this recommendation: If these bond wires get moved due to an accident or due to necessity for a repair, the wire should be considered bad. It should be pulled and replaced (if there are just a few per hybrid), otherwise the whole hybrid should be considered bad because a hybrid with a large number of replaced bonds cannot be considered as reliable. Such damaged hybrids/modules can be sent to CERN for repair as the required bond parameters and bond jig support may not be suitable at all centers.