1. FPIX Upgrade – Status of CO 2 Cooling Studies S.Grünendahl, FNAL for the FPIX Upgrade Mechanical Group H. Cheung, G. Derylo, S.G., S. Kwan, C.M. Lei, E. Voirin (Fermilab) K. Arndt, Q. Liu (Purdue) S.Grünendahl – CMS Pixel CO 2 Meeting1March 19, 2013

2. FPIX CO 2 Cooling Areas of Progress March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting2 Tests since previous meeting:: 2/12 1.4mm ID outer half-disk loop 2/14 1.4mm ID inner half-disk loop 2/21 1.6mm ID full length loop 2/27 Multi-blade disk w/TC 5022 pocket slots for blade-ring joint FEA study of through slot joint 3 Half Disks Port Cards and POH End Flange DC-DC converters Pipes and Cables CO2 cooling tubes and flex cables

3. Loop Tests Update Full length stainless steel tubing assemblies with dummy heat loads Measure temperatures vs. flow & pressure drop Initial finding: pressure drop larger than in simulation Adding concentric heat exchanger, to guarantee subcooled liquid, and fine-grained RTD placement to confirm transition to two-phase flow New studies: variations in tube diameter inner/outer half lengths configurations March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting3

4. Loop Setup March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting4 subcooler Fine grained RTD placement to locate onset of two-phase flow

5. 1.6mm ID Full Loop Test March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting5

6. Loop Tests: Combined Results March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting6

7. Loop Tests: Combined Results II March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting7

8. Joao’s Calculations Outer loop, full heat load, lowest stable experimental mass flow (0.65 g/s) and 1.5 times l.s.e.m.f. (1.07 g/s) March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting8

9. Joao’s Calculation I March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting9

10. Joao’s Calculation II March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting10

11. Calculation vs. Experiment Lots of discussion and progress on understanding of difference simulation vs. experiment Many calculations by Joao (Thanks!) My conclusion: all except Delta P seem to agree difference maybe not all that surprising: Even (easier) single phase flow depends a lot on parameters like e.g. tube roughness that are hard to control March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting11 (From Eric & Joao)

12. Loop Test Conclusion Both parallel (with 1.4mm ID) and serial (with 1.6mm ID) are viable Decision will have to take into account complexity, material accounting and redundancy/failure tolerance considerations March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting12

13. Multi-blade Tests: TC 5022 in Pocket Joints Improved joint geometry control (dry fit to equalize radial play for all blades before assembly) March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting13 A1silicon 1 ctr-12.35 A2silicon 2 ctr-12.61 A3silicon 3 ctr-12.82 A4Blade 1 ctr-12.49 A5Blade 2 ctr-12.85 A6Blade 3 ctr-13.40 A7silicon 1 i-13.07 A8silicon 2 i-13.39 A9silicon 3 i-13.15 A10silicon 1 o-13.34 A11silicon 2 o-13.94 A12silicon 3 o-13.67 A13Blade 1 i-13.29 A14Blade 2 i-13.70 A15Blade 3 i-13.53 A16Blade 1 o-14.42 A17Blade 2 o-14.90 A18Blade 3 o-14.68 B1Ring i 1-15.72 B2Ring i 2-15.16 B3Ring i 3-15.64 B4Ring o 1-16.35 B5Ring o 2-15.85 B6Ring o 3-16.39 B7silicon 4 ctr-11.70 B8Blade 4 ctr-12.00 B9silicon 4 i-13.05 B10Blade 4i-13.27 B11Ring i 4-15.22 B12silicon 4 o-13.16 B13Blade 4o-13.82 B14Ring o 4-16.29 B18tubing mid-18.45 B19tubing in-18.84 B20tubing out-19.67 -12.6 -12.8 -11.7 -12.9 -13.4 -12.0 -13.1 -13.4 -13.2 -13.9 -13.7 -13.2 -13.3 -13.7 -13.5 -14.9 -14.7 -13.8 -15.7 -15.2 -15.6 -15.9 -16.4 -16.3 ∆T=0. 3 ∆T=0.6 ∆T=- 0.3 ∆T=1. 0 ∆T=0. 6 ∆T=1. 0 ∆T=1.7 ∆T=2. 5 ∆T=0.2 ∆T=0. 3 ∆T=2.4 ∆T=1. 5 ∆T=2. 1 ∆T from CO2 to inner ring = 3.5 4.1 3.6 4.0 -13.1 -13.3 -15.2 ∆T=0. 2 ∆T=1. 9 -12.4 -12.5 ∆T=0.1 -13.3 -14.4 -16.4 ∆T=1. 1 ∆T=2. 0 ∆T from CO2 to outer ring = 2.9 3.4 2.9 3.0 ∆T from CO2 to silicon center = 6.9 6.7 6.4 7.6

14. Ansys vs. Experiment March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting14 Good match using data sheet material properties and nominal dimensions (i.e. no fudge factors)

15. Conclusion TC 5022 pocket joint fully qualified Necessary joint QC depends on blade manufacturing tolerances; in any case doable, even if a bit labor intensive March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting15

16. Blade-Ring Joint FEA Studies Motivation: Through slot might have practical advantages for half-disk assembly March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting16 Maximum Silicon Temperature Radial Thermal Conductance (W/m^2/K) 25102550 Axial Conductance 2 0.91 -2.50 -5.13 -8.30 -10.65 5-6.90 -7.70 -8.40 -10.14 -11.30 10 -10.03 -10.35 -10.59 -11.30 -11.83 25-12.00 -12.08 -12.30 -12.34 -12.50 50 -12.73 -12.76 -12.78 -12.86 -12.94 Maximum Silicon Temperature Radial Thermal Resistance (cm^2*K/W) 5210.40.2 Axial Resistance 5 0.91 -2.50 -5.13 -8.30 -10.65 2-6.90 -7.70 -8.40 -10.14 -11.30 1 -10.03 -10.35 -10.59 -11.30 -11.83 0.4-12.00 -12.08 -12.30 -12.34 -12.50 0.2 -12.73 -12.76 -12.78 -12.86 -12.94 Nominal joint parameters (material & thicknesses) Conclusion: radial heat transfer less important => might want to look at through slot again (Caveat: Studies without CF in joint area – repeat with CF)

17. Blade-Ring Joint FEA Studies II Better structural strength if carbon fiber cladding continues into joint pocket/slot Simulation looks ok March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting17

18. FPIX Cooling Layout ‘Decision Tree’ (from Kirk) March 19, 2013S.Grünendahl – CMS Pixel CO2 Meeting18 Left vs. Right HCs Symmetric (3 main lines) or Asymmetric (2+2 main lines) HD Inner + Outer in Series (1.6mm ID HD tubing) HD Inner + Outer in Parallel (1.4mm or 1.6mm ID HD tubing) 2 + 4 3 + 3 3 inners + 3 outers Outer-inner-outer + Inner-outer-inner

19. 291 396 η = 1.3 η = 1.6 η = 2.1 η = 2.5 2x8s Z loc. TBD shown 491mm from IP 161 45 2x8s Full geometry 19

20. η = 1.6 η = 2.1 η = 2.5 2x8s η = 1.6 η = 2.1 η = 2.5 2x8s Segmentation alternative #0 - Baseline - 1 st HD on one main line + 2 nd and 3 rd HDs in parallel on the other main line = two main cooling loops per Half-Cylinder 2 nd + 3 rd disks 1 st disks 3 hits 3.5 hits 3 hits 4 hits 3 hits 2 hits 20

21. η = 1.3 η = 1.6 η = 2.1 η = 2.5 2x8s η = 1.3 η = 1.6 η = 2.1 η = 2.5 2x8s Outer-inner- outer 4 hits 3 hits 2.5 hits Inner-outer- inner 3 hits 3.5 hits 2.5 hits Segmentation alternative #1 – two cooling loops per Half Cylinder (Total 4 cooling loops per end) 21

22. η = 1.6 η = 2.1 η = 2.5 2x8s η = 1.6 η = 2.1 η = 2.5 2x8s 22 Segmentation alternative #2 - All outers in parallel + all inners in parallel on two main cooling loops per Half Cylinder All Outers 4 hits 3.8 hits 1.5 hits All Inners 3 hits 2.5 hits 3.5 hits

23. η = 1.6 η = 2.1 η = 2.5 2x8s η = 1.6 η = 2.1 η = 2.5 2x8s Segmentation alternative #3 – three cooling loops per two Half- Cylinders (Total 3 cooling loops per end) 2 nd + 3 rd disks 1 st + 3 rd disks 3 hits 3.5 hits 3 hits 4 hits 3.5 hits 3 hits 23

24. η = 1.6 η = 2.1 η = 2.5 2x8s Segmentation alternative #3 – three cooling loops per two Half- Cylinders (cont.) (Total 3 cooling loops per end) 1 st + 2 nd disks 4 hits 3 hits 24

25. Summary  Loop tests show both parallel cooling loops with 1.4mm ID and serial loops with 1.6mm ID are viable solutions  Multi-blade tests: TC 5022 in pocket slot has been fully qualified for blade – ring joint  Further multi-blade assembly tests for carbonized and soldered joint are in preparation  Discussion on optimizing the FPIX cooling loop connection scheme is underway March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting25

26. Backup Slides Progress in related areas, from Purdue Delta p vs. flow for different diameters Tables for loop measurements March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting26

27. Designed custom front-end tools to pick-and-place HDI onto bare 2x8 bump-bonded modules. Semi-automated module assembly trials with prototype HDI will take place once these custom tools are fabricated. Work in progress to build a practical design and installation sequence for mounting, connecting, and cooling double-stacked port cards/POH in service (half) cylinders. Custom tools for pick-and-placing the HDI onto the 2x8 bump-bonded module Progress@Purdue (from Kirk):

28. Delta P vs. Flow March 19, 2013S.Grünendahl – CMS Pixel CO 2 Meeting28

29. Loop Measurement Tables March 19, 2013S.Grünendahl – CMS Pixel CO2 Meeting29