November 12, 2001 C. Newsom BTeV Pixel Modeling, Prototyping and Testing C. Newsom University of Iowa

November 12, 2001 C. Newsom Overview Vacuum Vessel Models Internal support structures Vacuum Interconnect Board HDI/Flex Cable tests MultiChip Module prototypes Materials testing

November 12, 2001 C. Newsom Vacuum Vessel Models Cylindrical Model Rectangular Model

November 12, 2001 C. Newsom Cylindrical Model

November 12, 2001 C. Newsom Cylindrical Model Shown here are cables from both front and back sides of the pixel module. Side cables must twist, stressing the pixel module non- symmetrically. Insufficient space for side cables

November 12, 2001 C. Newsom Rectangular Model Rectangular model has more space for side cables Cannot plug cables into the sides since there is a magnet pole behind it. Cooling manifold interferes with horizontal cables from the back of the module.

November 12, 2001 C. Newsom Internal Support Structures Integrated carbon support/manifold Carbon Half Barrel Structure

November 12, 2001 C. Newsom Integrated Carbon Support/Manifold The MultiChip Modules mount directly on the carbon manifold Pure carbon joints are not robust and need more research Manifold to Chip Module connections unsolved.

November 12, 2001 C. Newsom Carbon Half Barrel Design Barrel is double walled laminated carbon. Cables are moved to a side board. Space at bottom now available for motion, pump structures Insufficient space for HDI/daughter boards shown here. Major assembly problems

November 12, 2001 C. Newsom Vacuum Interconnect Board Carry ~35,000 signals from inside to outside the vacuum Constructed from 6 separate boards each with its own o-ring. Daughter cards have been removed to gain space. Ribbon cables pass through the surface and plug into the back side. Should we join the 6 boards, build a single board, …?

November 12, 2001 C. Newsom Vacuum Interface Board

November 12, 2001 C. Newsom HDI/Ribbon Cable Flexor One end is at -10C, and one at 25C to cool the power lines. Must absorb 2cm motion of half barrel during tuning. The cable must work in a vacuum.

November 12, 2001 C. Newsom MultiChip Module Prototypes Beryllium prototypes –Aluminum Modules (serpentine flow) –Aluminum Modules (parallel flow) –Stainless Steel Module (parallel flow) Fuzzy carbon prototypes –Initial Design –Improved Carbon Joints –Current Design

November 12, 2001 C. Newsom “Beryllium” Prototype Modules Serpentine flow 2mm channel (aluminum) Parallel flow 2mm channel (aluminum) Parallel flow 0.5mm channel (stainless steel)

November 12, 2001 C. Newsom Prototype Flow Test Results Parallel Channel Al Module Parallel Channel SS Module

November 12, 2001 C. Newsom Thermal Test Setup Measure temperatures using RTD sensors Heat both surfaces with brass heat spreaders on silicon wafers. Variable flow and heat input

November 12, 2001 C. Newsom Aluminum Module Heat Tests Heating curves at nominal 0.5W/cm2, both sides One liter/min flow

November 12, 2001 C. Newsom Temperature Results

November 12, 2001 C. Newsom Vibration Tests Vibrations perpendicular to the surface. Vibration vs flow from 0 to 1.5L/min Corrected for external vibrations All motions are below 1 micron

November 12, 2001 C. Newsom MCM Vacuum Test Vessel

November 12, 2001 C. Newsom Fuzzy Carbon Prototypes Thermal Prototype Mechanical Prototype Current Status

November 12, 2001 C. Newsom First Fuzzy Carbon Prototype Temperature drop of ~7 degrees (ok) Mechanically very weak Manifold joint failures

November 12, 2001 C. Newsom Mechanical Prototype This module looks very similar to the first prototype It differs in that the fibers are more randomized so that cross connects can strengthen the coupon Additional reinforcement at ends was added The module was considerably stronger but additional effort is needed Coupon still has joint problems

November 12, 2001 C. Newsom Carbon Carbon Joint Efforts Note effects due to 20% shrinkage Nanotubes added to increase joint strength Still much weaker than conventional epoxy

November 12, 2001 C. Newsom Ovalized Joined Tubing Original DesignOvalized Design Ovalized Glassy Carbon Tubes

November 12, 2001 C. Newsom Future Fuzzy Ovalized Carbon Modules Ovalized tubing provides thinner cross section Fibers connect more directly to the coolant tubes giving much better heat transfer Connected carbon tubes are considerably stronger The manifold joints clearly need more R&D

November 12, 2001 C. Newsom Materials Testing Stress and strain effects Vacuum effects Neutron activation Radiation Damage

November 12, 2001 C. Newsom Sound is a pulse with most components in the 1MHz range. Young’s Modulus Apparatus

November 12, 2001 C. Newsom Epoxy Study Can measure speed of sound to 0.5% From speed of sound, we can know Young’s modulus Will measure before/after effects of radiation, stresses, etc.

November 12, 2001 C. Newsom Neutron Activation Will modify an 80gram Pu/Be neutron source for activation studies Source is available indefinately Must test all materials and the products used to clean them!