1. Aluminum Clamshell Vacuum Chamber Development Plan
T. Fornek
July 11, 2007

2. Thanks to
Rodd Pope
Carl Rago
Karen Fant
Andy Haas
Dan Wright

3. Concept to Achieve Physics Design
“All Aluminum” Alloy
6061-T651 Clamshell Halves
6061-T651 Strongback
Al-to-SST Transition Inserts or Flanges
Discrete, End Pumping
Race Track Aperture, 5 mm x 12 mm
Support/Adjuster Common with ANL Design
Fabrication Process
Precision machined halves
Cleaned with Etch
Polished
Cleaned
Welded
Baked
Assembled to Strongback

4. Prototype Al Clamshell
Machined from stock,
mechanically polished

5. 2 Prototype Al Clamshells
Seam welded
Flanges welded
Flange hidden

6. 2 Prototype Al Clamshells with Al Strongback
Two Part Al Epoxy – Devcon Al Putty
(tack weld may be an option)
Flange hidden

7. Prototype Clamshells & Strongback on Adjuster Supports
Common Adjuster Support
Compatible
Flange hidden

8. Clamshells, Strongback, & Flange on Adjuster Supports
Vacuum Test Flange
Not production
Adjuster Support

9. Half-length Clamshell Assembly

10. 50% Length Vacuum Test Chamber on Adjuster Supports
Common Adjuster
Support Design

11. Remaining Parts

12. What Has Been Demonstrated
Machining process on half-length clamshell
Hand welding of clamshells
Hand welding of aluminum/stainless flanges to aluminum clamshell assembly
Epoxy bonding of clamshell to strongback
Polishing of flat coupons

13. What Needs to be Demonstrated
Machining process on full-length clamshell
Automated welding of clamshells
Polishing of clamshell
Effect of cleaning on polished surface
Effect of welding on surface finish
Bake-out and vacuum performance
Full length strongback fabrication

14. Current Plans
Pursue polishing of existing clamshells to demonstrate achievable surface finish
Development and Delivery Schedule
3 Months to Full Length Prototype
6 months to complete fabrication and delivery

15. End of Presentation