1. Theodore Todorov Pixel mechanics november 8th 2010 1 Inner detector upgrade / IBL Activities on cooling circuits @ LAPP LAPP team Jacky Ballansat, Patrick Baudin,Pierre-Yves David, Pierre Delebecque, Nicolas Massol,Thibaut Rambure, Theodore Todorov,Tamer Yildizkaya 1.Specifications 2.Current R&D goals and program 3.Fittings R&D 4.Stainless steel cooling loop 5.EB welding and brazing 6.Bending 7.Pipes order 8.Qualification and quality assurance

2. Theodore Todorov Pixel mechanics november 8th 2010 Cooling services for IBL 2 Inlet connectors Outlet connectors

3. Theodore Todorov Pixel mechanics november 8th 2010 3 Specifications (mainly for IBL) Functionnal: Maximum leak flow (He) : 10 -5 mbar.l.s -1 @1 bar Presure (bar): Xo (minimise) Radiation level : up to 1000 Mrad Temperature : mean = -35 °C (maxi +40 °C ; mini -60 °C) Pipes inner diameters : 0.8 to 3 mm Pipe material : Titanium grade 2 Pipe thickness : 0.1 to 0.3 mm depending on ID Available space for the fittings : less than  10 mm TestMax design service ultimate service normal CO21501007020 C3F825??1510 1 - Specifications

4. Theodore Todorov Pixel mechanics november 8th 2010 Connector positions for ID Upgrade 4 At end of staves Both SCT and Pixel At PP1 Both SCT and Pixel No manifolding in ID volume Manifold at PP1 Alternative for Pixel: Patch panel with manifold at end of pixel package Small connectors between staves and PPP Larger connectors & pipes between PPP and PP1

5. Theodore Todorov Pixel mechanics november 8th 2010 5 EB welding tests Bending tests 2 - Current R&D goals and program Ti Pipe/fitting linkageDismountable connexion of 2 pipes Bending of Ti pipes Ti Electron beam welding Custom fitting Industrial fitting STÄUBLI ? Brazing Brazing tests R&D program @ LAPP Fitting tests

6. Theodore Todorov Pixel mechanics november 8th 2010 6 Until recently, we were focused on development of the Fitting, optimizing the geometry and the properties of the different surfaces. We performed test in order to validate the different designs, focusing on the minimal torque needed to achieve leak tightness. Main developments The last few months we have also worked on the "commissioning" of the fittings for routine use by other labs, for the cooling loop tests (stainless steel) and for the next stave prototypes (Ti). This involved studying the usable torque range, in order to deduce a recommended torque and the tooling. 2 - Current R&D goals and program

7. Theodore Todorov Pixel mechanics november 8th 2010 7 Base line design Test @cold 4 combinations 1 MaleTA6V /1 femaleTA6V tested - OK 1 MaleTA6V /1 female Stainless steel tested - OK 3 –Fittings R&D Test @room temperature 21 combinations 1 MaleTA6V /1 femaleTA6V tested - OK 6 MaleTA6V /1 female Stainless steel tested – OK 2 tests to find ultimate torque : 8 N.m Many more combinations tested in variations of the design Tightness optimisation Define the optimal parameters (friction on the surfaces and the threads Tooling needed to control the torque

8. Theodore Todorov Pixel mechanics november 8th 2010 8 Spherical design Toroid design Misalignment influence (5°) 3 –Fittings R&D

9. Theodore Todorov Pixel mechanics november 8th 2010 9 Tests @ cold 3 –Fittings R&D – tests @cold

10. Theodore Todorov Pixel mechanics november 8th 2010 10 1.Hydraulic pressure test @ 150 bars @ room temp 2.He Leak test @20 bars @ room temp 3.Cooling from 20°C to -50°C 4.He Leak test @20 bars @ -50°C 5.Pressure test @ 150 bars @ -50°C 6.He Leak test @20 bars @ -50°C 7.Heating from -50°C to 20°C General tests procedure @ cold P T 20 -50 20 150 234 567 1 H20He 3 –Fittings R&D – tests @cold

11. Theodore Todorov Pixel mechanics november 8th 2010 11 Next steps The base line solution for PP1 is defined Increase the number of tested combinations with the base line design Keep on performing cold tests Thermal cycling (100 cycles) Simple tests with liquid CO2 (bottle) Determine the limits of use for pressure Study the tooling needed to control the torque Study the integration aspects 3 –Fittings R&D – next steps Optimized design will be studied OD reduced to 8mm (maybe 7 mm) Reduction of the amount of material

12. Theodore Todorov Pixel mechanics november 8th 2010 12 Cooling loop production and tests 3 –Stainless steel cooling loops Goal Cooling loop made of stainless steel will be tests @ Nikhef Production Pipes from Nikhef Fitting and bushings made @LAPP Brazing made by Bodycote -> new surface treatment made of graphite Production samples made of same components and brazed at the same time as the cooling lines tested @LAPP (QA procedure) Should be delivered on Week 46 Fitting tests Design developed for Ti -> need to be check for stainless steel

13. Theodore Todorov Pixel mechanics november 8th 2010 13 Stainless steel fitting Test @cold To be done 3 –Stainless steel cooling loops Test @room temperature 13 combinations 1 MaleTA6V /1 femaleTA6V tested - OK 2 tests to find ultimate torque : 8 N.m ->no leak Dismounting/mounting torque 4 N.m –No leak Dismounting/mounting torque 2 N.m –leak flow few 10 -7  Kept under 20 Bar He 2 hours : leak flow -> few 10 -9 to few 10 -8  Kept under 20 Bar He 17 hours : leak flow -> same evolution (He diffusion around the leak detector ?) 20 mounting/dismounting : OK

14. Theodore Todorov Pixel mechanics november 8th 2010 14 4 –EB welding and brazing Status 30 samples brazed and 30 EB welded, changing the material and the cleaning Finished Brazed an EB samples were tested @RT ->OK Cold tests on part of the brazed samples ->OK In progress Finish the cold tests (mostly finished, OK) Perform thermal cycling Metallographic analysis to be performed @CERN

15. Theodore Todorov Pixel mechanics november 8th 2010 15 Stainless steel cooling loops brazing Temperature : > 1000 °C Material 60%cupper / 40% Gold Issue : capillaries may be filled up ID 0.8 mm ID 2 mm 4 –EB welding and brazing

16. Theodore Todorov Pixel mechanics november 8th 2010 16 4 –EB welding and brazing-in situ brasing machine Goal Brazing the pipes during integration Device Vacuum chamber + heater (induction, infra red ?) Experts from Bodycote + …. Limitations Effects on the environment ? Control of the brazing ? !! Brainstorming !! Vacuum chamber Heaters