WELDING TESTS & OTHERS ISSUES SUMMARY WA104 PROJECT NEUTRINO EXPERIMENTS Jean-Pierre Brachet Gilles Favre Paula Freijedo Didier Lombard WA-104

INDEX INTRODUCTION PART 1: U-FRAME CORNER STATUS OF THE WELDING CONFIGURATIONS QUALITY LEVEL & NON-DESTRUCTIVE TEST (NDT) STRATEGY FOR ASSEMBLY TOOLING & MACHINING PART 2: EXTRUDED CORNER ASSEMBLY STATUS OF THE WELDING CONFIGURATIONS FOR THE CORNERS TO PANELS TEST PIECE VALIDATION QUALITY LEVEL WELDING OF THE U-FRAME TO EXTRUDED CORNER COMPONENTS DELIVERY 13/11/2015 WA-104

INTRODUCTION The aim of this presentation is summarize and clarify some points related to the the different welding configurations and other issues for the Cold Cryostat WA104 in the frame of the Neutrino Experiment, in order to set up and qualify the best solution for manufacturing. 13/11/2015 WA-104

STIFFENING FRAMES ALIGMENTS 1 To 5 – DRAWING: CEN104CR_0025 PART 2: EXTRUDED CORNER PART 1: FRAMES CORNER 13/11/2015 WA-104

PART 1: U-FRAME CORNER 13/11/2015 WA-104

1- WELDING CONFIGURATIONS 2 configurations for the U-Frame corner ACCORDING TO THE DRAWING CEN104CR_0026: Material: Aluminium EN AW-6082 T6 Thickness 20mm: MIG process (Details X1-X2-X5) Thickness 10mm: TIG process (Detail X3) 13/11/2015 WA-104

MIG PROCESS-20mm OF THICKNESS: Drawing for Welding Qualification STATUS: - Configuration and parameters of the pWPS: VALIDATED - Welder qualification: On-going - Welding Procedure Qualification (PQR): On-going Values taken during the tensile test of the PQR: Tensile strength Rm= 220 & 226 MPa Yield strength Re= 13/11/2015 WA-104

TIG PROCESS-10mm OF THICKNESS Drawing for Welding Qualification STATUS: - Configuration and parameters of the pWPS: On-going - Welding Procedure Qualification (PQR) & Welder qualification: Next step 13/11/2015 WA-104

2- WELDING OF A REAL CORNER Preliminary measurements of the Shrinkage on the real corner +/- 0.1mm +/- 0.15mm Shringkage Average 3.5mm L=250mm L=350mm Gap 10mm 3- QUALITY LEVEL & NON-DESTRUCTIVE TEST DURING PRODUCTION The required quality level for welds imperfections shall be level B according to the standard EN-ISO 10042:2005 NDT & sequence: 1º- Radiographic test or Ultrasonic examination (100%) NOTE: US requires FLATENNING on the welds 2º- Dye Penetrant NOTE: Defects reparation could be cause of CONTAMINATION 13/11/2015 WA-104

2 1 Cut and adjust the dimensions with the panel 3- STRATEGY FOR ASSEMBLY Fabrication the U piece whole with both corners welded: NOTE: The DIMENSION of the panel SHALL BE ensured - REPEATABLE PROPOSAL: Fabrication of the piece in 2 parts with only 1 corner welded Cut and adjust the dimensions with the panel 1 2 13/11/2015 WA-104

THE TOOLING FOR FRAME ASSEMBLY IS STORED IN THE BUILDING 156 Mounting of the tooling to be done (Marzio’s team could be help) The SCAFFOLDING is required 13/11/2015 WA-104

Specific portable milling machine for chamfering have been developed 5- MACHINING Dedicated milling machine for the U-frame components will be installed in the building 156 Specific portable milling machine for chamfering have been developed 13/11/2015 WA-104

PART 2: EXTRUDED CORNER ASSEMBLY 13/11/2015 WA-104

Material: Aluminium EN AW-6082 T6 Process: MIG 1- WELDING CONFIGURATIONS FOR EXTRUDED CORNER TO JOIN THE PANELS Material: Aluminium EN AW-6082 T6 Process: MIG 13/11/2015 WA-104

CERN TRIALS Results PRELIMINARY TEST: German proposal T15: T15mag x100 T15 MACRO: - Penetration: 10.38mm (from the root to the surface) Micro-Cracks[1001] at the root (red frame), not permitted according to the level B of NF-EN-ISO-10042. Few gas porosity [2011] permitted according to the level B of NF-EN-ISO-10042 <1% melt area. 13/11/2015 WA-104

Results PRELIMINARY TEST: - T14 CERN proposal: Results PRELIMINARY TEST: - T14 40º? T14 MACRO: Penetration 10.43mm (from the root to the surface) Few porosity [2011] permitted according to the level B of NF-EN-ISO-10042 <1% melt area Lack of fusion at the root [4013] not permitted according to the level B of NF-EN-ISO-10042 13/11/2015 WA-104

The piece will be tested in order to validate the design: 2- TEST PIECE The piece will be tested in order to validate the design: 3- QUALITY LEVEL & NON-DESTRUCTIVE TEST DURING PRODUCTION The quality level and the different possibilities for NDT to perform on the welds should be checked. 4- WELDING OF THE EXTRUDED CORNER TO THE U-FRAME The configuration for this joint will be discussed & defined 13/11/2015 WA-104

COMPONENTS DELIVERED U-FRAMES CORNERS By the end of this month First batch available Second batch to be defined U- FRAMES BEAMS ADDITIONAL EXTRUDED CORNER FOR TEST PIECES 13/11/2015 WA-104

THANKS FOR YOUR ATTENTION MERCI POUR VOTRE ATTENTION 13/11/2015 WA-104