1. IBL Mock Up IBL Mock Up MANUFACTURING 2011/04/29 François-Xavier NUIRY Maxence CURDY Andrea CATINACCIO CERN PH/DT/PO 1

2. Summary IBL Mock Up V01, aluminium staves Beam pipe manufacturing Mock up assembly procedure Thermal set up 2

3. IBL Mock Up V01 Staves Fabrication Process What we had : 3

4. IBL Mock Up V01 Staves Fabrication Process What we have : What we need if we want to respect geometrical envelops : 4

5. IBL Mock Up V01 Staves Fabrication Process 1- Setting the cutter head at 17⁰ 2- Machining the 14 aluminium parts to lower the angle [22 ⁰  17 ⁰] -Machining the parts to reduce the length [780 mm  748 mm] 3- Drill 2 holes with spacing of 736 mm 4- And finally machining 2 slots 1324 x14 5

6. IBL Mock Up V01 Ring Tool Manufacture of Ring Tool To hold the ring in position and be able to keep the spacing of 736 mm, we’ve designed ​​a Ring Tool with pins and a clamping system. Clamping System Pins 6

7. IBL Mock Up V01 Ring Tool A A A B B AB To keep the spacing between Rings during the assembly, the holes are perfectly located. 7

8. IBL Mock Up V01 Ring Rework Rings are made ​​in Stereolithography (SLAC) 1 - To machine holes for the screws, the ring is positioned on the Ring Tool : alignment, drilling Ф2mm and tapping M2.5 2- We’ve kept the same tool to drill the ring supports holes: alignment, drilling Ф1.2 and boring Ф1.5H7 12 x2 Ring support 8

9. IBL Mock Up V01 Parts Assembly 1- Staves are attached to the ring with screws M2.5 2- Ring supports are assembled to the ring through pins Ф1.5 3- Thanks to ring supports, the IBL prototype slides in the IST. (The IST inner surface roughness allows an easy insertion, without grease) 132 9 Mock up available for integration and thermal test!

10. Beam pipe manufacturing Functional specs Main objectives:  Getting a thermally active beam pipe, in order to simulate back out conditions Able to heat up to 250˚C Materials specified in the TDR Automatic temperature control, with systems anti over heat  Be able to perform some integration tests Internal envelop = 45mm External envelop = 55.7mm

11. Beam pipe manufacturing Materials used PartMaterialComments Tube [Beryllium]  Aluminium 6061 T6 (ρ=2.713, K=167 W/m.K) ID=44.68mm OD=46.78mm l=2.440m Supplier = Online metal [USA] Physical properties closed to beryllium (ρ=1.85, K=216 W/m.K) Heaters [Kapton heaters]  Watlow Silicon rubber heaters, 0.6mm thickness Cheaper than kapton heaters, but a bit more thick (0.6 instead of 0.2mm) Polyimide film Kaneka polyimide film, 2 layers (2*6μm)The original one used in current beam pipe Aerogel ASPEN aerogel 7mm thicknessRe-machined to lower the thickness  ~4 mm Polyimide film Kaneka polyimide film, 2 layers(2*6μm)The original one used in current beam pipe Glue Epotecny P101 Polyimide resin, resist up to 576 ˚C 125 g = 436 Euros ! Thickness not controlled Aluminium foil Standard aluminium foil 1 layer = 5μm

12. Beam pipe manufacturing Fabrication process 1- Machining the alu pipe to lower the thickness [1.6  1.05mm] 2- Mounting the pipe on the rolling support 3- Fix thermocouples 4- Mounting heaters (rolled around the tube)  5- Wrapping 2 layers of polyimide tape and cure it (1 hour at 200˚C) 6- Wrapping 1 layer of aerogel 7- Wrapping 2 layers of polyimide tape and cure it (1 hour at 200˚C) 8- Gluing the aluminium foil and cure it (1 hour at 200˚C) 1 2 5 and 7 3 6 : no picture du to the huge amount of dust in the room 4 Polyester shrinking tape before curing (removed after curing) 8: still not done, because we keep the possibility to check the heat dissipation with the Infra-red camera Auto-electric rack: Automatic temperature control

13. Beam pipe manufacturing Results What we haveWhat we tried to get A full thermo active beam pipe, able to heat up to 200˚C. We can heat up to 230˚C for few minutes. We did not heat up to 250˚C. This could damage heaters cables. An geometrical envelop globally controlled (Average outer diameter ~54.6 mm, without aluminium foil) This variation is mainly due to 2 reasons: -Non regularity of aerogel -presence of heater leads It is quite hard to wrap the aerogel on the pipe: It generates a lot of dust and controlling its thickness is not easy  we should order aerogel with the right thickness (3mm) for futures beam pipes 55.2 54mm

14. Beam pipe manufacturing Thermography Thermography during first cure (just a qualitative study) Global view during the heating step 50˚C / hour Impact of the thermocouple cable on the heat dissipation Heat dissipation at extremities: to be taken into account in the curing One heater receiving power during the heating step (normal behaviour) Thermography After having equipped the pipe with aerogel and polyimide tape. (200˚C fixed on the aluminium tube) Globally, we can say that we reach 86 ˚C on the outer surface of the polyimide tape, when the alum pipe temperature is set to 200 ˚C Extremities are now well heated thanks to the addition of heating jackets around the pipe This picture represent the length of the IBL. We can check that we globally have a homogeneous heat dissipation Some non regularities in heat dissipation come from the silicon heaters leads (thermally more conductive)

15. Mock up assembly procedure 15 Getting real staves for the IBL mock Up  Goal: Integration tests + thermal tests + Flex fixation test K13C Omega [0 90 0] K13C Face plate [0] K9 Allcomp foam Titanium pipes 2mm ID Dummy silicon sensors, able to heat up to 100 W on 1 stave

16. Mock up assembly procedure 16 Getting real staves for the IBL mock Up  Goal: Integration tests + thermal tests + Flex fixation test 1. We glue the foam on the pipe Foam + pipe assembly

17. 17 2. We glue the first assembly with Omega + EOS Calibration tool Mock up assembly procedure

18. 18 3. We machine the stave to get the right dimensions Mock up assembly procedure We put the assembly in the female vacuum tool. Stave assembly without face plate. Female vacuum tool. Extra foam and omega are to be cut by the diamond saw, in the Female mould.

19. 19 3. We glue the face plate on the foam Mock up assembly procedure Glue calibrator. Stave assembly without face plate. Face plate

20. Thermal set up Aluminium frame nearly ended 20 Black pipe = IST White pipe = Beam pipe Longitudinal and radial adjustment possible  Keep the co-axiality between IST and beam pipe