1. Cooling loops for prototype Staves
ATLAS Upgrade WP4 meeting
Lancaster University 4th Dec 2012
Cooling loops for prototype Staves
Update on cooling pipes progress
Confirmation of design of loop
Discussion on design developments of loops for future staves
Richard French - The University of Sheffield
Martin Gibson, John Matheson, John Hill, John Noviss – RAL
Ian Mercer - Lancaster

2. Tube stock availability
Production
Sample
Material
OD mm
ID mm
Wall um
length m
 Stock
Due
Offcut
Qty
P/S/O
CP2 Ti
3.175
2.775
200
2.2m 22 P
2.500
2.365
140
3.1m 1 S
2.275
2.025
125
3.0m 2 50
1.995 18
1.775
1.525 8
1.200
0.400 6
0.900
150
0.6m 4 17
1.000
0.450
275
0.360
270
0.800
0.500
0.750
0.490
130
0.670
0.405
132.5
0.595
0.330
316L SS
220
5.0m 14
1.8m 5 O
2.7m
750
2.0m
2.000 53
Aluminium
360 32
660 74
2.480 69
4.760
340
2.5m
Titanium capillaries and exhaust tubing due to be delivered 3rd December 2012.
0.80 x 0.50 & 1.20 x 0.90 = capillary development requiring normal tolerances with uniform dimensions.
Old Stave x = ( /-0.00mm Bore x /-0.025mm Wall)
New size x giving a bore 0.03mm smaller /-0mm Easier to weld – more robust.
In order to get 3 Metre+/-10mm Lengths, amended all the 50 Metre quantities to 51 Metres (i.e. 17 Lengths x 3M).
Trying 2.5mm OD x 140um wall; Standard (ish) OD & bombproof.
Prototype capillary tubing fresh from the mill has now reduced wall to
0.750mm OD x 0.490mm ID x mm Wall.
0.670mm OD x 0.405mm ID x mm Wall.
0.595mm OD x 0.330mm ID x mm Wall.

3. Vacuum Brazing 316L-CP2 Ti Problems all the way
First – Silver plating on nuts contaminated brazed joint
The VCR nut threads are silver plated to prevent gauling during assembly. This silver is reflowed during the furnace cycle = remove.
Latest – Cu plating is proving difficult to be uniformly coated down the narrow bore of the fitting
If proves impossible I will reduce the depth of the mechanical joint to allow better penetration of the Cu fitting.
Summary – it is still a Cu plating problem with the 316L fitting – the braze process works on larger items.
1/8” Ti to VCR
2.275mm OD Ti to VCR
1/8” Ti to VCR
NEW REFLOWED

4. Confirmation of design
Confirmation of design? Stave ‘09, Stave 250, Stave130 SMC, EoS arrrghghgh……

5. EOS – how does this shape up?
New z = 1.3m Stave end
John Noviss
What is length tube sticking out from stave end? Universal decision for 250.
EOS – how does this shape up?

6. Image of z=1.3 Stave end How much tube length is used in total up to this point?

7. Specifications Stave name Raw tube Bend radii EoS Y/N Z=0 radii
Comment
Stave 250
2.275mm; 1/8” Ti. 1/8” 316L N
Majority made in 316L SS. CP2 Ti on shelf in 1.8” OD & 2.275mm OD
Stavelet 250
None spare
Stave 130
2.275mm Ti
None made
Stavelet 130
Pressure drop
316L & CP2 Ti
Various parts made based on Stave 250, with and without SMC, 1.2 & 1.6m stave
PIXEL Disc
2.275mm OD CP2 Ti
1x half disc rough prototype made
Encapsulated joint
1/8” CP2 Ti
In work – one item to make based around?

8. From past planning Assuming we have minimal decisions made so rather vague or exceptionally obvious
Stave, Stavelet cooling circuits
Re-stock of cooling circuits and stavelet circuits. Include pressure testing > DATABASE entry.
Re-stocking of tube material and bending trials on capillary tubing
Pressure drop measurements –
Components part produced – design finalisation required
CO2 plant booking Feb13 see Richard Bates’ presentation later.
TIG Orbital Welding.
Reprogramming M200 and using grounding system from new system = part done
Gas purge over long distance and multiple manifold measurements/effects on weld quality = started
Measurements of electrode tip angle – arc gap and power v weld quality = 2013
Finalised electrode – seeking mass production or tooling to make in house. = 2013
Continuing to refine Swagelok weld head for heat sinking and improved tube alignment. = on going
Bring online the InterPulse system and test on 2.275mm OD 125um wall CP2 Ti. = part done / on going / slow
Laser welding
Hopefully see Ian Mercer’s presentation for an update from Mike..
Material reduction
Changing bulbous sleeve joint to butt weld on 125um tube with tooling from PIPE ltd. = Slow as small sizes
Reducing mass in capillary tube wall – production limits. = Done
Fittings
Vac brazed stubs full statistical trial. = VERY SLOW and still waiting for test pieces
CP2 ti fittings – material sourced from Sandvik. Need to check cost out v custom fitting from Swagelok or Fti plus the effort put in at QMUL. = Material rubbish – won’t weld.
Re-manufacture of 6LV VCR thin wall fittings as run out. = Done
Thermal shock etc in the pipe line at some point – hardware almost completed at RAL. = ¾ done
Burst testing of circuits to see where calculated headroom is v actual – mass reduction maybe. = ISIS contacted ????