1. Advanced Composites for Next Generation Scientific Instruments Year 2 2015 LDRD Call Physics Division RPM Session E.Anderssen 1, K.Chow 1, M.Garcia-Sciveres 2, M.Gilchriese 2, L.Greiner 3, C.Haber 2 *, J.Silber 1, James Nasiatka 5, J. Urban 4, H.C. Wang 2, and C.Swenson 6 (1)Engineering, (2)Physics, (3)Nuclear Science, (4)Materials Science, (5)ALS, (6)AFRD/SuperCon, (*)PI Long Term Funding: construction projects for detector or accelerator systems totaling ~10-15 M$

2. Overview This multi-divisional LDRD proposal is aimed at evaluating and acquiring technical concepts and capabilities which could be crucial elements of future instrumentation for high energy, relativistic heavy ion, astro-particle physics, and accelerator components. These elements bear particularly on requirements for thermal performance, scale, reliability, compatibility, and precision. This proposal leverages prior investments and expertise developed in the participating divisions and in the LBNL Composites Laboratory. This is a Year 2 request to continue work already underway.

3. Approach Technologies proposed for study involve advanced materials which combine excellent mechanical and thermal properties. – Ultimately suitable for large scale applications and fabrication. Typically these materials are composites or derivatives of carbon, polymers, and other organic or inorganic fillers. – Seek to explore new and emerging materials which require special processing methods and may expand Lab capabilities. Understand these materials through both measurements, and simulation and modeling tools. Integrate materials into prototypical structures which can be used to qualify overall system-like performance. Build a new knowledge and experience base at the Lab which can position us to lead in the thermal/mechanical aspects of future large scale instruments for fundamental and applied science.

4. Connections Physics and NSD: Support structures for trackers at HL/HE-LHC, Liner Colliders, Electron-Ion Colliders. AFRD: Potting materials for high field superconducting magnets Photon Science/ALS: Vacuum compatible structures for end-stations, beam dumps, accelerator components MSD/Molecular Foundry: nanoparticles for thermal loading; materials, dispersions, process development

5. Example Application electronics Carbon fiber Carbon foam coolant Always seek an optimization which minimizes mass while retaining good thermal/mechanical characteristics

6. FY14 Status Low density foam – Samples produced by SBIR supported collaborator, 2nd SBIR awarded for FY15. Preparing for tests with a air-flow Venturi system here. Pore characterization process developed to allow correlation with theoretical models. Enhanced polymers – Collaboration with MSD in place. Materials system selected (C.E. + BN), curing process tested, thermal conductivity measurement system procured and in use. Superconductor Potting – RTM compatible CE resin samples acquired, components for cure calorimetry studies being assembled Vacuum compatible polymers – Baseline materials have been characterized by CXRO, optical bench structure Large area inspection – Tubular imaging concept demonstrated on long interconnected assemblies, control and analysis system created and used – Components procured for large linear inspection configuration Non-destructive testing – Deliberate defect samples fabricated – Acoustic detection of these defects demonstrated on bench to 10 mm (!!) – Nanometric surface probe re-commissioned for this application – In process of scaling this up to a large system demonstrator

7. Carbon foam before hollowing of ligands Laminate sample with hidden defect, excited by piezoelectric disc, under measurement with laser 5  m surface vibration observed Thermal conductivity probe Imaging system for precision inspection Surface profile Feature detection in image

8. Plans for FY15 Low Density Foam and Air Flow Cooling: construction of air flow demonstrator module and “pixel” support beams Loaded Polymers: determine best formulation, characterized, and scaling understood, integrated into CF facings, cured, and measured High Temperature Composites: “optical bench” test vehicle studied in a variety of materials Superconducting Magnets: cure structure built with CE, loaded and unloaded, mechanical and thermal testing Large Area Inspection: system tested and demonstrated on multiple long structures, control and analysis software Nondestructive Testing: piezo+nanometric probe fully demonstrated and scaling to full size process understood

9. Budget Total request is (pre-G&A): $339K (FY14 request $476K, de-scoped to $278K) Request covers: – Salaries for engineers, scientists, technicians – Procurements of consumables and tools – Subcontract to foam development firm – Travel

10. Extra Slides

11. New Materials and Processes Hollow ligand carbon foam: lower densities Thermally loaded resins and adhesives for toughness, higher-K, crack resistance – Recent study shows dramatic improvement in thermal conductivity with low volume % loading of nanoparticulates – Increased strength and temperature range helps performance of superconducting magnets. High temp pre-pregs compatible with metal joining & vac. bake-out Advanced co-cured thermal/mechanical/electronic laminates Large area precision inspection – 2D and 3D metrology Precision assembly Non-destructive testing for hidden defects High temperature processing

12. Demonstrators Sandwiched structures: staves, cylinders, sections with integrated cooling, heat transport, and electrical components Low density foam based support for gas flow cooling Composite vacuum vessels and beam pipes High K resins for high field superconductors and laminates Vessels and components for low background experiments Measurement and QC capabilities for large scale fabrication projects.

13. Tasks Task 1: Design/build/test staves with low density foam (PD, EG) Task 2: Develop polyimide matrix process (EG) Task 3: Design/build high temperature compatible “beamline” component prototype (EG/ALS) Task 4: Study/feasibility of loaded resins, adhesives (PD,EG,MSD,MF) Task 5: Application of loaded resins to superconducting coils (EG,AFRD) Task 6: Gas cooling of foam structures (NSD,EG) Task 7: Research use of acoustic microscopy, samples studies (PD,EG) Task 8: 3D metrology study, determine useful tools/concepts (PD) Task 9: Precision/high speed inspection tools based upon custom image acquisition and analysis (PD) Task 10: Precision assembly and placement tools study (PD,NSD,EG) Task 11: Co-cure with embedded electronics (PD,EG) Task 12: Low background materials for 3D printing (NSD,PD,EG)

14. Example: Tasks 4-5 First phase would determine fillers and recipes Bulk samples would be made and tested for thermal conductivity and other properties Then apply to detector component fabrication prototypes Second phase would be to understand best choices for Supercon application Develop test process Create and test potted components and magnet

15. State of the Art FEA measurement Structures Co-cured laminations Low density/ Hi-K Foam Analytical models

16. Capabilities for New Instruments New MaterialsNew Tools Demonstrators

17. Resources Composites Lab – Technical team ~50% effort – Engineering Post-doc Molecular Foundry Superconducting magnet test facility ALS Engineering