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IBL Mock Up

IBL Mock Up MANUFACTURING

2011/04/29François-Xavier NUIRY

Maxence CURDYAndrea CATINACCIO

CERN PH/DT/PO

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Summary

• IBL Mock Up V01, aluminium staves

• Beam pipe manufacturing

• Mock up assembly procedure

• Thermal set up

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IBL Mock Up V01 Staves Fabrication Process

What we had :

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IBL Mock Up V01 Staves Fabrication Process

What we have :What we need if we want to respect geometrical envelops :

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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 mm748 mm]

3- Drill 2 holes with spacing of 736 mm

4- And finally machining 2 slots

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x14

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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

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IBL Mock Up V01 Ring Tool

A

ABA B To keep the spacing

between Rings during the assembly, the holes are perfectly located.

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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

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Ring support

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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)

1 32Mock up available for integration and thermal test!

Beam pipe manufacturingFunctional 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

Beam pipe manufacturingMaterials used

Part Material Comments

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 thickness Re-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 P101Polyimide resin, resist up to 576 ˚C

125 g = 436 Euros !Thickness not controlled

Aluminium foil Standard aluminium foil 1 layer = 5μm

Beam pipe manufacturingFabrication process

1- Machining the alu pipe to lower the thickness [1.61.05mm]2- Mounting the pipe on the rolling support3- Fix thermocouples4- 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 aerogel7- 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)

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5 and 7

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6 : no picture du to the huge amount of dust in the room

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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

Beam pipe manufacturingResults

What we have What we tried to getA 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

Beam pipe manufacturingThermography

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)

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Mock up assembly procedure

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

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Mock up assembly procedure

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

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2. We glue the first assembly with Omega + EOS

Calibration tool

Mock up assembly procedure

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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.

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3. We glue the face plate on the foam

Mock up assembly procedure

Glue calibrator.

Stave assembly without face plate.

Face plate

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Thermal set up

• Aluminium frame nearly ended• Black pipe = IST• White pipe = Beam pipe• Longitudinal and radial adjustment possible Keep the co-axiality between IST and beam pipe