1. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 1 ATLAS Pixel Support Tube PRR: Parts Pixel Support Tube Production Readiness Review Parts Overview Alexis Smith February 18, 2003

2. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 2 ATLAS Pixel Support Tube PRR: Parts Overview Schematic of Pixel Support Tube assembly List of Parts Method of production for each part Materials Tools Lay-up procedure Cure procedure Pre-assembly processing Comparison of prototype to production parts

3. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 3 ATLAS Pixel Support Tube PRR: Parts Schematic of PST Assembly The Pixel Support Tube Assembly comprises the shell, the rails on which the pixel detector slides, the mount connections to the SCT, and the thermal isolation system

4. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 4 ATLAS Pixel Support Tube PRR: Parts List of Parts PST Shell Laminate –Forward Shell (2) –Barrel Shell (1) PST Flange Assembly –Flange (6) –Backing Ring (6) Mount Pad (6) Flat Rail (9) Vee Rail (3) Hoop Stiffener (57) Heater System Assembly –Heaters (108) –Mount Pad Circuits (6) –Wires (357) Various machined and other parts –Pixel mount –Mount block –Mount insulator shim –Mount insulator pad –Wire harness –Adhesive –Connector (Flexures)

5. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 5 ATLAS Pixel Support Tube PRR: Parts Shell Laminate Fiberglass mat, EX1515U, [0,0,+60,-60] S 8-ply symmetric lay-up of YSH-80 (carbon) and AQ-II (fiberglass) with a layer of fiberglass mat to prevent carbon particle liberation Plies are cut to allow for axial and circumferential interweaving 0 degree 60 degree -60 degree (2 nd layer

6. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 6 ATLAS Pixel Support Tube PRR: Parts Shell Laminate 0 plies laid-up separately and with tension -60 and +60 plies stacked and pre-compacted before lay-up Stack is compacted on mandrel after each new layer application Heater panels layed-up as last step before cure Prototype: plies interleaved in the hoop direction Production: plies interleaved in hoop and axial directions

7. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 7 ATLAS Pixel Support Tube PRR: Parts Shell Laminate Production mandrel will be 2500 mm long Production shell laminates shall be 457.5 mm OD Barrel shell length: 1631 mm Forward shell lengths: 2276.5

8. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 8 ATLAS Pixel Support Tube PRR: Parts PST Flange Assembly: Flange [+/-45, +/-45, +/-45] 3-ply involute lay-up of CN60 strips with 2/3 overlap of each strip Lay-up on flange tool with collar

9. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 9 ATLAS Pixel Support Tube PRR: Parts Trimming of Flange Flange lip is trimmed to size with a router on a trim plate

10. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 10 ATLAS Pixel Support Tube PRR: Parts PST Flange Assembly: Backing Ring [0/90,+/-45, 0/90,+/-45, 0/90,+/-45, 0/90,+/-45] S 16-ply lay-up of CN60 cloth in alternating orientations Total post-cure thickness is 4 mm Lay-up a large ring out of which the backing ring is cut

11. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 11 ATLAS Pixel Support Tube PRR: Parts Trimming of Backing Ring Water-jet cut backing ring out of large lay-up Cut bevel with router on the same trim plate as the flange

12. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 12 ATLAS Pixel Support Tube PRR: Parts Mount Pad [0/90,0/90,+/-45, +/-45, 0/90,+/-45, 0/90, +/-45, +/-45, 0/90,0/90] 11-ply quasi-symmetric lay-up of CN60 cloth Darts are used to ensure proper conformance to tool shape

13. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 13 ATLAS Pixel Support Tube PRR: Parts Mount Pad Part is trimmed on a custom vacuum chuck

14. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 14 ATLAS Pixel Support Tube PRR: Parts Flat and Vee Rail EX1515, [0/90, 0/90, 0/90, 0/90, 0/90, 0/90, 0/90] 1 ply of EX1515 followed by 7 plies of P30 cloth Stacks of 3-4 plies are pre-compacted before being layed- up Part trimmed to length on the tool Tool is supported during cure to minimize out-of- straightness

15. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 15 ATLAS Pixel Support Tube PRR: Parts Hoop Stiffener [+/-45,0/90,+/-45] 3-ply CN60 lay-up Dart to ensure proper conformance to tool shape Made in 3 parts

16. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 16 ATLAS Pixel Support Tube PRR: Parts Heater Panel Custom-made part supplied by vendor Kapton with copper sputter-coated on both sides, Aluminum foil on one side, polymer coverlay on the other side. Heater traces and connection pads etched onto copper. 4 positive leads and 1 negative to allow for multiple connection possibilities Connection points for EMI shielding Jumper across mount pad area

17. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 17 ATLAS Pixel Support Tube PRR: Parts Heater Panel Shell with co-bonded heater panels

18. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 18 ATLAS Pixel Support Tube PRR: Parts Flexure Mounts 3 Flexures, 1 Solid Block Made of Titanium Still in design phase

19. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 19 ATLAS Pixel Support Tube PRR: Parts Machined and Other Parts Pixel mount Mount block Mount insulator shim Mount insulator pad Wire harness Adhesive (Hysol 9396) Connector

20. FEBRUARY 2003 Pixel Support Tube A. Smith LBNL 20 ATLAS Pixel Support Tube PRR: Parts Comparison of Prototype to Production Parts Successfully built all composite parts except hoop stiffeners –Shell laminate with heater panels –Flange and backing ring –Flat and Vee rails –Mount pads Length of shell prototype is shorter and shell lay-up method is slightly different. Plies will be the same. All other components are equivalent to production parts.