1. Thermal Shield Connection Study
Niklas Templeton
15/02/16

2. Thermal Shield Connection Study
Updated connection configuration
FE Model
Steady State Thermal Results
Welded shield
Pipe with integrated connection
Separate connection
Al6061 Pipe
SS316 Pipe
Static Structural – Thermal Contraction
Pipe and Panel Stress Comparison

3. FE Model – Connection Proposal
2 Floating clamp connections for FPC thermalisation
Top circuit modified for assembly purposes
9 Lateral Fixed connection points (100 mm long)
FPC load applied directly to clamp
HOM Coax heat load applied at Panel Interface

4. Boundary Conditions Heat Loads: see table Pipe 50-70 K Gradient
Intercept
Heat Load (W)
Qty
Total (W)
FPC 55 2
110
HOM Coax
12.0 6 72
Blades 7 4 28
Tuner 5 10
CWT 1
222
Heat Loads: see table
Pipe K Gradient
Radiation: 1.7 W/m2 Flux applied all external surfaces
Titanium Fixations: T=295 K at OVC interface
Material Properties: see graph
All thermal contact connections: 200 W/m2K (unless otherwise stated) for conservative results
Assuming no contact between pipe and panels other than at connection points

5. Shield Thermal Gradient
Welded Connections
Pipe Connection
Shield Thermal Gradient
T min (K)
T max (K)
Welded
50.3
90.1
Ideally bond between Pipe-Fillet & Fillet-Panel
Conclusions:
T max is concentrated at HOM Coax 6, can be improved.
Results are promising
Connection configuration to be carried forward
Ease of manufacture & assembly
Shield not over-constrained

6. Connection Comparison
3. Separate Connector Al Pipe*
1. Welded Connection
2. Integrated Connector*
4. Separate Connector SS Pipe*
Ideally bond between Pipe-Fillet & Fillet-Panel
Contact resistanc between Connector-Panel
Contact resistance between Pipe-Connector & Connector-Panel 2.
*Contact area scaling factor required
Estimated as 1:3

7. Thermal Contact Conductance
167 W/m2K
250 W/m2K
500 W/m2K
Thermal Contact Resistance Measurements for indirectly cooled SR Optics, B Fell & K Fayz, Daresbury Laboratory 2013

8. 2. Integrated Connector 666.7 W/m2
Contact resistanc between Connector-Panel
Pipe Connection
Thermal Contact Conductance (W/m2K)
Scaled Thermal Contact Conductance (W/m2K)
Shield Thermal Gradient
T min (K)
T max (K)
Welded -
50.3
90.1
Integrated Connector
2000
666.7
58.8
96.4
1500
500.0
61.4
98.4
1000
333.3
66.3
102.3
500
166.7
77.7
113.7
166.7 W/m2

9. 3. Separate Connector Al Pipe
Pipe Connection
Thermal Contact Conductance (W/m2K)
Scaled Thermal Contact Conductance (W/m2K)
Shield Thermal Gradient
T min (K)
T max (K)
Welded -
50.3
90.1
Integrated Connector
2000
666.7
58.8
96.4
1500
500.0
61.4
98.4
1000
333.3
66.3
102.3
500
166.7
77.7
113.7
Non-integrated connector (Al Pipe)
64.6
101.1
68.7
104.5
75..2
111.3
93.1
130.7
666.7 W/m2
Contact resistance between Pipe-Connector & Connector-Panel
166.7 W/m2

10. 4. Separate Connector SS Pipe
Pipe Connection
Thermal Contact Conductance (W/m2K)
Scaled Thermal Contact Conductance (W/m2K)
Shield Thermal Gradient
T min (K)
T max (K)
Welded -
50.3
90.1
Integrated Connector
2000
666.7
58.8
96.4
1500
500.0
61.4
98.4
1000
333.3
66.3
102.3
500
166.7
77.7
113.7
Non-integrated connector (Al Pipe)
64.6
101.1
68.7
104.5
75..2
111.3
93.1
130.7
Non-integrated connector (SS Pipe)
67.8
105.1
96.2
137.8
666.7 W/m2
Contact resistance between Pipe-Connector & Connector-Panel
666.7 W/m2

11. Engineering Data – Thermal Expansion

12. Cool Down Deformation Welded Shield

13. Cool Down Deformation Welded Shield

14. Cool Down SS Pipe

15. Cool Down SS Pipe