1. 3D Printing Developments
Francois-Xavier Nuiry
Giulia Romagnoli
Tobias Polzin
Edouard Grenier Boley
Romain Gerard EN-MME-FW
With the support of TE-VSC

2. 3D Printing Technology Validation
3D printing design is innovative for a dump
R&D necessary to validate the technology before installing it inside accelerator
Design challenges:
Material porosity
Wall thickness between cooling channels and vacuum
Mechanical fatigue
Thermal fatigue
Water erosion
Particle damage fatigue
Test pieces produced to validate the design
12/10/2016
PS Internal Dump Core Review

3. 3D Printing Part Used @ CERN
Interest towards metal 3D printing is been growing at CERN
Parts already installed in the accelerators/detectors and several tests are going on…
In particular, regarding 3D printing in Ti6Al4V there are:
A cooling circuit installed in the core of the CMS experiment
Several forks of rotary beam wire scanners installed in the SPS
Validation tests going on inside the VSC group
X-band applications (several tests going on…)
Cooling loops of the CMS PLT detector
SPS Fork of rotary beam wire scanner
Ti6Al4V 3D printed
Installed since 2014
Radiation environment
1.7 m from IP
60 mm from beam pipe
Under water pressure
Ti6Al4V 3D printed
Fast movement /Fatigue
Radiation environment
Installed in Jan 2015
Under vacuum (10-9 mbar)
100 mm
Proved non-contamination of powders
Outgassing rate ~ 6x10-9 mbar l s-1cm-2, H20 eq. after 10 hours pumping
Wall thickness 0.4 mm
He tight
Pressure 15 bar
* Ray Veness
* EDMS #
* Contact: Robert Loos EP-DT-CO
12/10/2016
PS Internal Dump Core Review

4. 3D Printing for X-Band Applications
X-band prototypes for high power test:
Integration with water cooling system
Application under vacuum
Specimens in Ti6Al4V for material characterization:
Vacuum: leak tightness OK ( 10-4 mbar inside the piece and He outside)
Mechanical strength and metallurgy
Shape accuracy and microtomography
Outgassing tests
Operation with cooling and vacuum:
Water ~ 25° C and 2/3 bar
VACUUM 2e-9mbar
Wall thickness 1.2mm
* Contact: Alexej Grudiev BE-RF-LRF
12/10/2016
PS Internal Dump Core Review

5. Metallographic and Mechanical Tests
* Test done by MME EDMS #
3T RPD
AM company
INP
Grenoble Institute of Technology
Concept Laser
3D printing machines
TENSILE TESTS
Company
Emod (GPa)
Rp0.2 (MPa)
A %
UTS (MPa)
3T RPD
112 ± 1
1097 ± 8
2 ± 0
± 3.0
INP
51 ± 0
830 ± 36
11 ± 2
904.8 ± 20.4 CL
108 ± 1
825 ± 11
12 ± 3
893.4 ± 10.7
Laser Sintering process
Electron Beam Melting process
Laser Sintering process
Conclusions:
Porosity is better with LS than EBM
Metallography for INP and 3T is similar to casted alloy
Tensile tests:
CL similar to annealed alloy
3T similar to solution treated
INP similar properties to the annealed alloy but low elastic module due to high porosity
12/10/2016
PS Internal Dump Core Review

6. Metallographic and Mechanical Tests
* Test done by MME EDMS #
3T RPD
INP CL
TENSILE TESTS
Company
Emod (GPa)
Rp0.2 (MPa)
A %
UTS (MPa)
3T RPD
112 ± 1
1097 ± 8
2 ± 0
± 3.0
INP
51 ± 0
830 ± 36
11 ± 2
904.8 ± 20.4 CL
108 ± 1
825 ± 11
12 ± 3
893.4 ± 10.7
LS process
EBM process
LS process
Conclusions:
Porosity is better with LS than EBM
Metallography for INP and 3T is similar to casted alloy
Tensile tests:
CL similar to annealed alloy
3T similar to solution treated
INP similar properties to the annealed alloy but low elastic module due to high porosity
LS selected as technology process
12/10/2016
PS Internal Dump Core Review

7. PS Internal Dump Tests Pieces
Produced by 3T
2 test pieces in Ti6Al4V with Direct Metal Laser Sintering (DMLS) technology
3D printed TEST parts to validate the design
Brazing test
Electro Beam Welding Test
Leak tightness test with He
Pressure tests with water
Vacuum tests
Metallurgy test on the assembly
Tomography check
Printing direction
100 mm
3D printed specimens for:
Tensile tests
EBW tests
Outgassing
Leak tightness
* in collaboration with EN-MME thanks to Romain Gerard
12/10/2016
PS Internal Dump Core Review

8. PS Dump Test Pieces Planned Tests
FIRST foreseen tests:
Machine internal diameter
Ti housing connection to the blocks: brazing test
Machine welding key for EBW test
EBW test to weld the 2 dump parts bout a bout
Welding 2 parts due to limits of length in 3D printing
First brazing tests on going…
Brazing procedure validation in the following weeks!
CDD numbers:
PS_TDIL_0009 / PS_TDIL_0010
Tests in collaboration with EN-MME
12/10/2016
PS Internal Dump Core Review

9. PS Internal Dump Core Review
Pieces for EBW Tests
Cylinders for EBW test
Plates for EBW test
EBW test on going… Procedure validation in the following weeks!
CDF numbers:
PS_TDIL_0011
PS_TDIL_0014
Tests in collaboration with EN-MME-FW
12/10/2016
PS Internal Dump Core Review

10. VSC Group Leak Tightness Tests
Leak tightness tests with membranes
VACUUM He
INITIAL
SLM (EOS machine)
3 different thicknesses (TH) in SS, Ti and Al:
0.25 mm
0.5 mm
0.75 mm
Ti not leak tight in the 3 thicknesses!
12/10/2016
PS Internal Dump Core Review

11. Membranes Specimens for Leak Tests
TEST done with sensor sensibility of 1E-10 mbar l/s He during 10 seconds
Thickness
Orientation
RESULT
0.25 mm XY
leak Z
étanche
45°
0.5 mm
0.75 mm
1 mm
1.5 mm
2 mm
2.5 mm
Problems to manufacture thin membrane (0.25)
Tests in collaboration with TE-VSC thanks to Ludovic Mourier
12/10/2016
PS Internal Dump Core Review

12. Outgassing and Tensile Tests
OUTGASSING TEST still on going…
Cleaning:  Procédure de dégraissage avec machine aux solvants MEG
12 specimens not HIP (foreseen test on HIP samples)
Chamber size: Ø 4 cm x 27 cm
room temperature 20°C
Specimens total surface: 246 cm2
Total outgassing: 2.2E-12 mbar l/s
BG outgassing: 1.3E-12 mbar l/s
Specific outgassing: 3.6E-15 mbar l s-1 cm-2
Tests in collaboration with TE-VSC thanks to Marco Morrone
TENSILE TESTS foreseen
- 24 tensile tests specimens for outgassing tests and tensile tests
12 with HIP treatment
12 without HIP
Metrology Ra measures done to study the influence of Ra on mechanical properties
Design conform to ASTM E8
Tests in collaboration with EN-MME-MM
12/10/2016
PS Internal Dump Core Review

13. PS Internal Dump Core Review
Conclusions
3D printing in Ti is a very promising technology
STI is taking advantage of this project to “innovate” for challenging materials for BIDs.
Collaborating with VSC in order to have clear acceptance procedures for 3D printed systems
Results obtained:
He leak tightness with wall thickness ≥ 0.5 mm
Low outgassing levels
Tensile strength comparable with annealed alloy
Further tests are necessary before validate the technology for beam intercepting devices
Porosity controls
Mechanical fatigue
Thermal fatigue
Particle damage fatigue
Materials response to high long term radiation damage
Water erosion
Testing of a prototype target in HiRadMat in early 2018
12/10/2016
PS Internal Dump Core Review

14. PS Internal Dump Core Review
Thank you!
12/10/2016
PS Internal Dump Core Review

15. Tensile Tests Foreseen
12 with HIP treatment
12 without HIP
24 tensile tests specimens for outgassing tests and tensile tests
Design conform to ASTM E8
Identification number written on every specimen
Tests in collaboration with EN-MME-MM
12/10/2016
PS Internal Dump Core Review

16. PS Internal Dump Core Review
Metrology Results - Ra
Ra measures on the dump pieces
Zone 1
Zone 2
Zone 3
Zone 4
Zone 5
Piece
Zone
Orientation
Ra (en µm)
Rz (en µm) 1
Zone 1
90°
9.26
55.35
Zone 2
11.63
72.21
Zone 3
11.60
74.11
Zone 4
+ 45°
12.64
71.53
Zone 5
- 45°
17.75
83.96 2
12.43
72.28
9.44
60.95
9.70
58.66
22.55
101.82
21.29
109.14
Rugosimeter MITUTOYO SJ 301
Palpeur conique 60° pointe diamant (rayon de points : 2µm)
Longueur de base = 2.5 mm
Longueur d’évaluation = 12.5 mm
Estimation de l’incertitude de mesurage : 10 % de la valeur du paramètre
Tests done by EN-MME-MM – EDMS numbers: J J
12/10/2016
PS Internal Dump Core Review