1. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 1 GLAST Large Area Telescope: Tracker Subsystem WBS 4.1.4 6D: Composite Panel Fabrication Thomas Borden Stanford Linear Accelerator Center Tracker Subsystem Engineer tborden@slac.stanford.edu Gamma-ray Large Area Space Telescope

2. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 2 Agenda Facilities Tray Description and Types Manufacturing Flow Plan Tooling Quality Assurance Trays Production and EM Results Conclusions

3. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 3 Facilities Carbon- Fiber Wall Plyform SpA, Varolo Pombia; Prime Contractor to INFN for Tray Fabrication and Assembly, –Subcontractor for closeout machining –Subcontractor for insert machining INFN Pisa; ESPI Test of bare panels –Holographic test –System can detect de-lamination defects in face sheets, between face sheet and honeycomb and between face sheets and closeouts Centrotecnica, Milan; Tray vibration testing of panels with bias circuits and tungsten –Qualification levels –Verification of fundamental frequency –Workmanship

4. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 4 Tracker Mid Tray

5. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 5 Tray Types Tray TypeHoneycomb Core Face sheet Plies Tungsten Converter MID1 lb/ft 3 43% Xo LIGHT1 lb/ft 3 4NO HEAVY3 lb/ft 3 618% Xo TOP1 lb/ft 3 43% Xo BOTTOM3 lb/ft 3 6NO

6. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 6 Manufacturing Plan Production Flow Diagram Machine Closeouts (outside Vendor) Dimensional Verification of Closeouts Install Inserts ref I.L. 02-117 & I.L. 02-118 Dimensional Verification of inserts Incoming Material receiving Inspection ref I.L. 02-105 Face Sheet Lay-up ref I.L. 02-106 Assembly of Face Sheet with Honeycomb with Redux 312 UL Assembly of Face Sheet/Honeycomb and Closeouts ref I.L. 02-118 Dimensional Verification and ESPI Testing (workmanship)

7. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 7 Manufacturing Plan Production Flow Diagram Cont. Assembly of Tungsten to Panel Ref I.L. 02-118 Assembly of Bias Circuits to Panel Ref I.L. 02-118 Final Trimming and Cleaning Ref I.L. 02-116 Final Dimensional Verification, weighing and QA Ship to INFN Ref I.L. 02-119 All assembly processes per LAT-PS-01584 Workmanship Vibration Testing at Centrotechnica

8. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 8 Tooling All assembly tooling documented and released All assembly tooling, and procedures, “proof tested” with EM hardware Additional copies of “standard” tray tooling in production Sufficient tools available to support production rate of 10 standard, 4 thick, one top and one bottom tray(s) a week

9. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 9 Tooling Tray assembly bottom plate Tray assembly top plate

10. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 10 Tooling Closeout bars

11. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 11 Tooling Closeout Insert Assembly Tool

12. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 12 Quality Assurance All processes controlled by ISO approved procedures at Plyform (I.L. 02-111, I.L. 02-112, I.L. 02-113) Regular INFN-Pisa oversight at Plyform Data Base Developed Nonconformance Reporting –Plyform nonconformance reporting system per I.L. 02- –LAT-PS-01584 specifies the following major Nonconformance reporting limits require halting production: Rejection during dimensional inspection of more than 4 of the trays produced out of a continuous sample of 40 trays. Rejection during dynamical tests of more than 4 of the trays produced out of a continuous sample of 40 trays. Accidents resulting in irreparable physical damage (serious enough for tray rejection) to more than 2 of the trays produced out of a continuous series of 40 trays.

13. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 13 Data Base Main form: select tray type access all tray data Tray data sheet: assembly data bare panel measurements final tray measurements (TBD) subcomponents IDs and data click on buttons to access details Luca Latronico – INFN Pisa

14. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 14 Data Base continued Bare panel dimensions (after clicking on dimensions button): plots measurements of reference points along tray structure plots sides BD/AC flatness, orthogonality, parallelism seen by moving slide bar Luca Latronico – INFN Pisa Luca Latronico – INFN Pisa`

15. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 15 Data Base continued Luca Latronico – INFN Pisa Each submask containing detail measurements data and has a clickable legend for reference – MCM legend shown here for example

16. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 16 Data Base continued Luca Latronico – INFN Pisa Connected to Ladders DB – this mask tracks ladders IDs, location and currents (pre- encapsulation and post- encapsulation) as measured at G&A/Mipot. Location/names given according to LAT-TD-00376 convention, e.g.: F – Front Side B - Back Side 0 - connected to FE 0 side …. 3 – connected to FE 23 side

17. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 17 GLAST:Gamma Ray Large Area Telescope Trays Production & E.M. Results R. Bagagli INFN - sez. Pisa

18. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 18 E.M. Tray Production Tray nameFace sheethoneycombTungsten Top4 plies1lb/ft 3 3%Xo Mid4 plies1lb/ft 3 3%Xo Light4 plies1lb/ft 3 // Heavy6 plies3lb/ft 3 18%Xo Bottom6 plies3lb/ft 3 // Defective4 plies1lb/ft 3 //

19. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 19 1) Dimensional Check procedure on the tool: - measure the tool in six points with a caliber - fill a form to compare the reference values with the measured values - If measured values are otuside ±0.03mm, then the operator has to adjust the lateral wall and to check again the value E.M. Results: ASSEMBLING IMPROVEMENTS

20. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 20 -The glue fills all the bonding area - The exceeding quantity goes out and will be removed in Refining Step Glue-line on the sandwich with dispenser on the bonding area (to avoid no-bonding area) Vacuum bag at standard temperature (to avoid air inclusion) E.M. Results: ASSEMBLING IMPROVEMENTS

21. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 21 Reference wall Upper plate Tray Skin Lower plate Tray assembly tool Tungsten assembly tool Kapton assembly tool Trimming tool Tray assembly tools toolIn houseUnder construction total assembly tool 347 Tungsten tool 213 Kapton tool 112 Trimming tool 101 Tray assembly rate capability: 3 trays/day

22. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 22 E.M. Results: DIMENSIONS

23. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 23 E.M. Results: FLATNESS

24. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 24 E.M. Results: ORTHOGONALITY & PARALLELISM

25. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 25 E.M. Results: TRAY DATABASE

26. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 26 Tests

27. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 27 Bare Panel: N.D.I. Test

28. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 28 Bare Panel: N.D.I. Test Honeycomb – Skin debonding ESPI: Thermal Loads very effective to detect bare panel defects Honeycomb crash Skin-closeout debonding

29. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 29 TG07: Bare Panel + W + Bias Plane ESPI: Vibration TEST 817Hz first resonance mode 1860Hz second resonance mode

30. GLAST LAT ProjectMarch 24, 2003 6D Tracker Peer Review, WBS 4.1.4 30 Conclusions All documentation in place. Database in place. Production Readiness Review scheduled for April 15, 2003. All tray materials needed are delivered or on order and will be available before need date. Tray production will begin on May 1, 2003