1. (Tim Jones)

2.  Who am I? ATLAS-UK Tracker Upgrade work-package leader for WP4 (Mechanics)  Materials, Cooling, Stave Core Assembly, Module Mounting, Test/Shipping Container, Integration  £4M + 53Sy effort  Historical Context – vertex detector support structures for physics at the Enerey Frontier Layer-00 (CDF – Fermilab) VeLo (LHCb – CERN)  Current Work ATLAS sLHC Tracker Upgrade Strip tracker staves ATLAS sLHC Tracker Upgrade Forward pixel staves  Facilities Carbon-fibre assembly QA  Future Directions 10/10/11 2 Carbon-fibre Development at Liverpool

3.  2001 Layer-00 (CDF – Fermilab) R ~ 15mm 128/256 channel wide sensors Two-part support structure in high thermal conductivity carbon fibre with embedded cooling tubes  2007 VeLo (LHCb – CERN) 42 T300/epoxy paddles with CF / TPG / CF sandwich baseboards In the 10 years from 2000 to 2010 the Liverpool group designed, fabricated & installed carbon-fibre based vertex detector support systems in two experiments at the energy frontier. 10/10/11 3 Carbon-fibre Development at Liverpool

4.  Local Support (Stave) Low mass, highly integrated support structure for 24 single-sided modules. 1200 x 120 x 5mm  Materials High thermal conductivity UD pre-preg  800 W.mK -1 Mitsubishi K13D2U  Tencate RS3 cyanate ester resin (EX-1515 lower cure temp) Thermally conducting foam  0.55 g/cc Pocofoam (closed cell)  0.26 g/cc Allcomp foam (open cell) Thin-wall cooling tubes  1/8” OD x 0.22mm stainless-steel  2.275mm OD x 0.14mm titanium cooling Low density cores  Ultracor UCF-126-3/8-2.0 (carbon fibre honeycomb – 0.032 g/cc)  Schutz Cormaster N636 3/16-1.7 (low CME N636 para-aramid paper/phenolic – 0.028 g/cc)  Reticulated Vitreous Carbon (RVC) foam (0.05 g/cc)  SiC foam 10/10/11 4 Carbon-fibre Development at Liverpool

5.  Stavelet (500mm x 120mm x 5mm) 3 stavelet cores delivered to international module programme Used as development programme studying stave thermo- mechanical properties and tooling / assembly procedure development 10/10/11 5 Carbon-fibre Development at Liverpool

6. -32°C -25°C 10/10/11 6 Carbon-fibre Development at Liverpool

7. Step 1 Step 2 Attempt to reduce glue mass (~ 10% for conventional build) by using resin in pre-preg to attach face sheet to core components. ItemMass (g) Side 1 (Side Rohacell)28.15 Side 2 (Mid Rohacell)24.49 Ti tube & fittings25.11 Extra Rohacell piece0.08 Side 1 + ext Rohacell +BN30.48 Est BN mass2.25 Side 2 + BN glue26.93 Est BN mass2.44 3rd Pre-preg Layer5.19 Constituent Mass87.71 Measured Mass87.42 10/10/11 7 Carbon-fibre Development at Liverpool

8.  Co-curing: Attach bus-tape to facesheet using pre-preg resin Elimination of glue layer reduces mass and thermal imprdance Issues with differential CTE affecting geometry and face sheet stress Theoretical modelling using Classical Laminate Theory Autoclave cures for full length stave Press cures for full length stave Autoclave cures for 0.5mm stavelet on CF Tooling 10/10/11 8 Carbon-fibre Development at Liverpool

9.  Transverse thermal conductivity not needed for thermal runaway with 130nm ASICs  Remove ~ 50% of CF  Lamination of power tape to CF lattice before stave assembly (Hysol 9396, 25  C, 5bar, 24h) 10/10/11 9 Carbon-fibre Development at Liverpool

10.  First attempt to manufacture full foam-core structures Top CF Plate Bottom CF Omega PEEK end-blocks Pocofoam cooling channel Low density RVC foam S/steel cooling tube Departures Stainless steel cooling tube – 2.0mm OD Fasteners in end-blocks M1.6 – perpendicular to flat face (not inclined faces) 10/10/11 10 Carbon-fibre Development at Liverpool

11. 10/10/11 11 Carbon-fibre Development at Liverpool

12.  K13D2U/RS3 face sheets  Allcomp 0.26 g/cc foam  2.275mm OD titanium tube Full foam core using Allcomp foam

13.  Plasma Cleaner Reinhausen PZ1  Glue Mixer Speedmixer DAC150  Autoclave 1.7m x 0.6m dia 200C / 100psi  Pattern Cutter Gerber 10/10/11 13 Carbon-fibre Development at Liverpool

14. 10/10/11Carbon-fibre Development at Liverpool 14  Strain Measurement (Vishay P3) CTE of CF structures CTE of BN filled Hysol  Advanced NDT Bondascope Pitch-catch for face sheet to honeycomb bond quality Resonance for face sheet de- lamination  Lloyd Instruments LRXPlus 5kN Materials Tester Tensile strength, modulus, 3-pt bend … etc  PosiTest Pull-off Adhesion Tester Adhesive bond tensile strength

15.  Liverpool have significant pedigree in developing CF support structures for vertex detectors  Expertise being applied to development of multi- module local supports (staves) for strip and pixel regions of ATLAS Tracker Upgrade  Significant investment in infrastructure / technical expertise  Technical developments focused on tight integration between thermal, electrical & mechanical aspects Light-weight thermally conducting foams Tube to foam interfaces Glue-less assembly 10/10/11Carbon-fibre Development at Liverpool 15