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THERMAL TEST CYCLES (Updating 15/7/2010)

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1 THERMAL TEST CYCLES (Updating 15/7/2010)
Anastasia Xydou University of Patras

2 Contents : Manufacturing flow for test disk stracture Naming of disks
Classification of RF disks Bonding and Thermal profiles Cleaning procedure Packaging and shipping

3 Main steps of manufacturing flow for samples:
Machining QC (Ra and flatness measurement ) Cleaning Microscopic observations QC (Ra and flatness measurement ) Heat treatment Bonding (VDL disks) Packaging and shipping Baking

4 Total disks =345 (including the reference pieces)
186 RF disks (d=12mm). a) 48 disks b) 138 disks main steps for the 128 disks: 99 RF disks (d=80/85 mm). main steps for the 96 disks : main steps: machining cleaning Heat treatment SEM DC sparks machining cleaning Heat treatment XPS The rest 10 are the (References) H2 content baking Machining Ra and flatness measurement Cleaning Heat treatment Microscopic observations bonding (VDL disks) Baking The rest 3 are the (References)

5 iii. 60 RF elliptical disks
main steps for the 50 disks: Heat treatment ESD Machining Cleaning The rest 6 are the (References) and the 4 are spare disks

6 Naming of disks : Every single disk has his own name the right sequence for understand its name is: One example is: Number cleaning method  Firm/University  Heat treatment  Temperature Size Firm/University (CERN) Temperature (820 °C) The number of the RF disk. 43 _ W C V B Cleaning procedure (w/o etching, only solvent) Heat treatment ( V Vacuum) Disks at d=80/85 mm

7 P S T H 104 W C V B / C P B A 082 S h L Argon at few mbar
All the possible combinations are: P S T H W C V B / C P B A S h L Argon at few mbar PVA TSINGHUA H2 at 1bar 1040 °C Elliptical samples SLAC etching W/O etching (only solvent) vacuum CERN Passivation Disks (d=80/85mm) BODYCOTE 820 °C SLAC H2 at few mbar LISTEMANN R  REFERENCE PIECES (all stay at CERN)

8 Production - surface after heat treatment DC sparks - XPS - H2 content
Concentrated tables : Production - surface after heat treatment 820 C 1040 C REFERENCE Vacuum Argon (mbar) HYDROGEN (mbar) H2 (1 bar) HYDROGEN(mbar) w/o etch Passivation SLAC etch CERN 1 2 21 Bodycote 36 PVA 12 SLAC Tsinghua Listemann 6 d=85/80 mm 4 99 Launched 30 pcs 85 mm (kugler) SEM 70 pcs 80 mm launched Hydrogen (mbar) H2(1 bar) 9 18 3 d= 12 mm 48 DC sparks - XPS - H2 content 10 46 68 24 8 138 Vacuum dynamics 200 pcs mm launched 14 56 elliptical samples

9 HYDROGEN means H2 at a few mbar
Separated information about each Firm or University : CERN VACUUM 820 VACUUM 1040 ARGON 1040 TOTAL d=80mm 6 18 d=12mm 15 45 Elliptical samples 27 81 SLAC H2 1040 H2 820 TOTAL d=80mm 6 12 d=12mm 15 30 Elliptical samples 8 14 29 27 56 BODYCOTE VACUUM 820 ARGON 820 Hydrogen 820 VACUUM 1040 ARGON 1040 Hydrogen 1040 TOTAL 140 d=80mm 6 36 d=12mm 15 11 86 Elliptical samples 18 21 27 23 TSINGHUA H2 1040 H2 820 TOTAL d=80mm 6 12 d=12mm 3 9 18 PVA ARGON 820(20 mbar) Hydrogen 1040 TOTAL d=80mm 6 12 d=12mm 3 9 18 LISTEMANN H2 1040 d=80mm 6 d=12mm 3 TOTAL 9 HYDROGEN means H2 at a few mbar

10 A table to control the amount of disks:
FIRM/UNIVERSITY D=12 mm D= 80 mm Elliptical disks TOTAL AMOUNTS OF DISKS (FOR EACH FIRM) CERN 45 18 81 SLAC 30 12 14 56 BODYCOTE 86 36 140 TSINGHUA 6 ---- PVA LISTEMANN 3 9 TOTAL AMOUNTS OF DISKS( FOR EACH SHAPE) 176 96 50 322 +23 RP =345 322 TOTAL AMOUNT

11 References(taken by Sergio)
48 RF disks (d=12mm) : References(taken by Sergio) 9 at CERN 1_WCV082 2_WCV104 3_WCA104 66_PCV082 67_PCV104 68_PCA104 131_SCV082 132_SCV104 133_SCA104 18 at BODYCOTE 16_WBV082 17_WBA082 18_WBh082 19_WBV104 20_WBA104 21_WBh104 81_PBV082 82_PBA082 83_PBh082 84_PBV104 85_PBA104 86_PBh104 146_SBV082 147_SBA082 148_SBh082 149_SBV104 150_SBA104 151_SBh104 6 at PVA 46_WPA082 47_WPh104 111_PPA082 112_PPh104 176_SPA082 177_SPh104 6 at SLAC 48_WSH082 49_WSH104 113_PSH082 114_PSH104 178_SSH082 179_SSH104 6 at TSINGHUA 58_WTH082 59_WTH104 123_PTH082 124_PTH104 188_STH082 189_STH104 3 at LISTEMANN 60_WLH104 125_PLH104 190_SLH104 61_WCR 62_WCR 63_WCR 64_WCR 65_WCR

12 128 RF disks (d=12mm) plus 10 references:
36 at CERN 4_WCV082 5_WCV082 6_WCV082 7_WCV082 8_WCV104 9_WCV104 10_WCV104 11_WCV104 12_WCA104 13_WCA104 14_WCA104 15_WCA104 69_PCV082 70_PCV082 71_PCV082 72_PCV082 73_PCV104 74_PCV104 75_PCV104 76_PCV104 77_PCA104 78_PCA104 79_PCA104 80_PCA104 134_SCV082 135_SCV082 136_SCV082 137_SCV082 138_SCV104 139_SCV104 140_SCV104 141_SCV104 142_SCA104 143_SCA104 144_SCA104 145_SCA104 68 at BODYCOTE 22_WBV082 23_WBV082 24_WBV082 25_WBV082 26_WBA082 27_WBA082 28_WBA082 29_WBA082 30_WBh082 31_WBh082 32_WBh082 33_WBh082 34_WBV104 35_WBV104 36_WBV104 37_WBV104 38_WBA104 39_WBA104 40_WBA104 41_WBA104 42_WBh104 43_WBh104 44_WBh104 45_WBh104 87_PBV082 88_PBV082 89_PBV082 90_PBV082 91_PBA082 92_PBA082 93_PBA082 94_PBA082 95_PBh082 96_PBh082 97_PBh082 98_PBh082 24 at SLAC 50_WSH082 51_WSH082 52_WSH082 53_WSH082 54_WSH104 55_WSH104 56_WSH104 57_WSH104 115_PSH082 116_PSH082 117_PSH082 118_PSH082 119_PSH104 120_PSH104 121_PSH104 122_PSH104 180_SSH082 181_SSH082 182_SSH082 183_SSH082 184_SSH104 185_SSH104 186_SSH104 187_SSH104 99_PBV104 100_PBV104 101_PBV104 102_PBV104 103_PBA104 104_PBA104 105_PBA104 106_PBA104 152_SBV082 153_SBV082 154_SBV082 155_SBV082 156_SBA082 157_SBA082 158_SBA082 159_SBA082 160_SBh082 161_SBh082 162_SBh082 163_SBh082 164_SBV104 165_SBV104 166_SBV104 167_SBV104 168_SBA104 169_SBA104 170_SBA104 171_SBA104 172_SBh104 173_SBh104 174_SBh104 175_SBh104 References 126_PCR 127_PCR 128_PCR 129_PCR 130_PCR 191_PCR 192_PCR 193_PCR 194_PCR 195_PCR

13 96 RF disks (80/85 mm) plus 3 references:
18 at CERN 1_WCV082B 2_WCV082B 3_WCV104B 4_WCV104B 5_WCA104B 6_WCA104B 34_PCV082B 35_PCV082B 36_PCV104B 37_PCV104B 38_PCA104B 39_PCA104B 67_SCV082B 68_SCV082B 69_SCV104B 70_SCV104B 71_SCA104B 72_SCA104B 36 at BODYCOTE 7_WBV082B 8_WBV082B 9_WBA082B 10_WBA082B 11_WBh082B 12_WBh082B 13_WBV104B 14_WBV104B 15_WBA104B 16_WBA104B 17_WBh104B 18_WBh104B 40_PBV082B 41_PBV082B 42_PBA082B 43_PBA082B 44_PBh082B 45_PBh082B 46_PBV104B 47_PBV104B 48_PBA104B 49_PBA104B 50_PBh104B 51_PBh104B 73_SBV082B 74_SBV082B 75_SBA082B 76_SBA082B 77_SBh082B 78_SBh082B 79_SBV104B 80_SBV104B 81_SBA104B 82_SBA104B 83_SBh104B 84_SBh104B 12 at PVA 19_WPA082B 20_WPA082B 21_WPh104B 22_WPh104B 52_PPA082B 53_PPA082B 54_PPh104B 55_PPh104B 85_SPA082B 86_SPA082B 87_SPh104B 88_SPh104B 12 at SLAC 23_WSH082B 24_WSH082B 25_WSH104B 26_WSH104B 56_PSH082B 57_PSH082B 58_PSH104B 59_PSH104B 89_SSH082B 90_SSH082B 91_SSH104B 92_SSH104B 12 at Tsinghua 27_WTH082B 28_WTH082B 29_WTH104B 30_WTH104B 60_PTH082B 61_PTH082B 62_PTH104B 63_PTH104B 93_STH082B 94_STH082B 95_STH104B 96_STH104B 6 at Listemann 31_WLH104B 32_WLH104B 64_PLH104B 65_PLH104B 97_SLH104B 98_SLH104B References 33_WCRB 66_PCRB 99_SCRB

14 50 RF elliptical samples plus 6 references,
plus 4 extra pieces: 18 at CERN 1_WCV082C 2_WCV082C 3_WCV104C 4_WCV104C 5_WCA104C 6_WCA104C 19_PCV082C 20_PCV082C 21_PCV104C 22_PCV104C 23_PCA104C 24_PCA104C 37_SCV082C 38_SCV082C 39_SCV104C 40_SCV104C 41_SCA104C 42_SCA104C 18 at BODYCOTE 7_WBA082C 8_WBA082C 9_WBh082C 10_WBh082C 11_WBh104C 12_WBh104C 25_PBA082C 26_PBA082C 27_PBh082C 28_PBh082C 29_PBh104C 30_PBh104C 43_SBA082C 44_SBA082C 45_SBh082C 46_SBh082C 47_SBh104C 48_SBh104C 14 at SLAC 13_WSH082C 14_WSH082C 15_WSH104C 16_WSH104C 31_PSH082C 32_PSH082C 33_PSH104C 34_PSH104C 49_SSH082C 50_SSH082C 51_SSH104C 52_SSH104C 53_SSH104C 54_SSH104C References 17_WCRC 18_WCRC 35_PCRC 36_PCRC 55_SCRC 56_SCRC

15 Disks 80/85 mm Some difficulties in classification: Disks 12 mm
W/O etching (Solvents) disks 1-65 Disk missing: 12 WCA104 Two same disks: 3_WCA104 (one of two took the missing’s name) Reference disks taken by Sergio 61_WCR 62_WCR 63_WCR 64_WCR 65_WCR Passivation disks Four disks don’t have classification codes: 107, 108, 109 & 110 (From now on spare disks) SLAC etching disks Reference disks instead of passivation cleaning had SLAC etching: 191, 192, 193, 194 & 195 PCR  SCR (change of code) Disks 80/85 mm W/O etching (Solvents) disks 1-33 OK! Passivation disks 34-66 Disk missing: 63_PTH104B Replacement disk: 72_SCV104B SLAC etching disks 67-99 Disks missing: 70_SCV104B & 72_SCA104B Replacement disks: 100 & 101

16 Thermal trends for each thermal cycle :
820 Vacuum VACUUM BRAZING FURNACE V1 - BRAZING PALCUSIL5 OR SCP1 Vacuum .Pumping 90 min - vacuum < mbar Level of homogenization Increase 5 °C/min T°C :790°C +/- 10°C pcs TP : 2H pièce +1H/-0min Level of Brazing Increase 2 °C/min T°C : 820°C MINI pièce TP : 0 min +1/-0 setting Observation 825°C SET POINT IN FURNACE Cooling Up to 600°C pcs +/-50°C Cooling turbine -5 PSI under argon Process Time(min) (1)→(2) .Pumping 90 min - vacuum < mbar, 20C 90 (2)→(3) Increase 5 °C/min Up to 790 C 160 (3)→(4) 2H piece +1H/-0min, 790 C 120 (4)→(5) Increase 2 °C/min up to 820°C 15 (5)→(6) Cooling up to 600°C 60 (6)→(7) Cooling turbine -5 PSI under argon (20C) 215 5°C/min  300°C/60 min600°C/120min 790°C/160min 2°C/min 20°C/10min 30°C/15min 4°C/min240°C/60min

17 820_PPArgon VACUUM BRAZING Process Time(min) (1)→(2) 90 (2)→(3) 160
FURNACE V1 - BRAZING PALCUSIL5 OR SCP1 Vacuum .Pumping 90 min - vacuum < mbar Put in PPArgon l/h - 10mbar Level of homogenization Increase 5 °C/min T°C :790°C +/- 10°C pcs TP : 2H pièce +1H/-0min Level of Brazing Increase 2 °C/min T°C : 820°C MINI pièce TP : 0 min +1/-0 setting Observation 825°C SET POINT IN FURNACE Cooling Up to 600°C pcs +/-50°C Cooling turbine -5 PSI Process Time(min) (1)→(2) .Pumping 90 min - vacuum < mbar (20C),Put in PPArgon-2400l/h-10mbar 90 (2)→(3) Increase 5 °C/min Up to 790 C 160 (3)→(4) 2H pièce +1H/-0min,790 C 120 (4)→(5) Increase 2 °C/min up to 820°C 15 (5)→(6) Cooling up to 600°C 60 (6)→(7) Cooling turbine -5 PSI (20C) 215 5°C/min  300°C/60 min600°C/120min 790°C/160min 2°C/min 20°C/10min 30°C/15min 4°C/min240°C/60min

18 1040_H2(both for 10mbar and 1bar )
VACUUM BRAZING FURNACE V1 Vacuum .Pumping 90 min - vacuum < mbar Under PPH2 – 10mbar – 2400 L/H Increase 5 °C/min T°C :1040°C +/- 10°C TP: 1H30 pièce +/-10min SET POINT IN FURNACE 1043°C Reduction 4 °C/min up to 800°C FURNACE T°C : 850°C +0/-20°C FURNACE at 800°C Transition in high Vacuum Cooling Cooling turbine -5 PSI Process Time(min) (1)→(2) .Pumping 90 min - vacuum < mbar 90 (2)→(3) Increase 5 °C/min Up to 1040 C 210 (3)→(4) 1H30 pièce +/-10min,to 1040 C (4)→(5) Reduction 4 °C/min up to 800°C 60 (5)→(6) Cooling turbine -5 PSI 5°C/min  300°C/60 min900°C/180min 1040°C/210min 4°C/min240°C/60min

19 Compulsory changes according to the firms-universities offers :
AWAITING OFFER FOR FREE (in the framework of the collaboration) SLAC H2 1040 H2 820 TOTAL d=80mm 6 12 d=12mm 15 30 Elliptical samples 8 14 29 27 56 After contacting with SLAC and Tsinghua, it was compulsory for the main schedule to be changed to the beside heat treatment processes. Both of them, couldn’t run at 10 mbar Hydrogen pressure. ONLY at 1bar. TSINGHUA H2 1040 H2 820 TOTAL d=80mm 6 12 d=12mm 3 9 18 AVAILABLE OFFER PVA ARGON 820(20 mbar) Hydrogen 1040 TOTAL d=80mm 6 12 d=12mm 3 9 18 Because of the past bad experiences at PVA with Argon partial pressure processes at about 5 mbar (due to plasma formation and burning of the heating insert), proposed to run at the 20 mbar pressure for the Argon process  AVAILABLE OFFER. LISTEMANN H2 1040 d=80mm 6 d=12mm 3 TOTAL 9

20 CERN BODYCOTE AVAILABLE OFFER : 500 (vacuum) or
ARGON 1040 TOTAL d=80mm 6 18 d=12mm 15 45 Elliptical samples 27 81 AVAILABLE OFFER : 500 (vacuum) or 1000 (Argon) CHF per cycle. At total = 2000 CHF BODYCOTE VACUUM 820 ARGON 820 Hydrogen 820 VACUUM 1040 ARGON 1040 Hydrogen 1040 TOTAL d=80mm 6 36 d=12mm 15 11 86 Elliptical samples 18 21 27 23 140 AVAILABLE OFFER : All the samples must be transferred together, in order to be used together and only for once to the heat treatment cycle of the cleaning of furnace-tool and before each series. Due to the difficulties in the stabilization at 10 mbar, it must be mentioned that the Argon pressure, will be at 5 mbar. The TOTAL OFFER rises to € .

21 Drilling (20-22/4) d=80/85mm Preparation before the drilling.
The drilling of the RF-disks (opening hole at least d=3mm). Compulsory procedure before the cleaning due to the special clips which are used to handle the disks during the cleaning process

22 Classification-Packaging before cleaning
The two views of the two different RF-disks (d=12mm and d=80mm). As it is visible, each disk has a special number on the one side (the other is for the thermal tests.) A try for the RF-disks, to be categorized to three teams according to the three cleaning procedures. Each disk is installed to a special small bag, according to the cleaning method.

23 Cleaning procedure : CLEANING TOTAL
All the RF disks after the installation to the clean room (after received from Kugler) Classified to special plastics bags (each bag has a special label with a special number) Collected in short teams according to the below schedule and transferred to the Surface treatments workshop, for the cleaning step. CLEANING W/O etching Passivation SLAC etching TOTAL d=80mm 33 99 d=12mm 60 66 186 Elliptical samples 18 20 56 111 117 113 341 341 After the cleaning procedure and the agreement with the firms/universities, all the RF disks would be transferred for the heat treatment procedure, in order to get simulated to each thermal cycle.

24 A l’attention de : Monsieur LEBET Serge V/ réf. DP/ Sté : CERN Tél :
DEVIS N/réf. VS Villaz, le 09/03/10 A l’attention de : Monsieur LEBET Serge V/ réf. DP/ Sté : CERN Tél : Affaire suivie par : Raymond SAEZ Fax : Madame, Monsieur, Nous vous remercions de votre demande de prix ci-dessus référencée et vous indiquons nos conditions pour le traitement de vos pièces : DESIGNATION : ESSAI BONDING/BRASAGE TEST SURFACE Poids Unit.= de dim. : MATIERE : CUIVRE CARACTERISTIQUES A OBTENIR : TRAITEMENT PROPOSE QTE Poids (en Kg ) * Unité Prix en Euros HT Mini de TTH HT REALISATION DE DIVERS CYCLE THERMIQUE AVEC ECHANTILLON POUR TEST DE SURFACE SUR FOUR V1 COMPRENANT : - HEAT TREATEMENT OF CLEANING FOR FURNACE AND TOOL BEFORE EACH SERIES 1 FORFAIT 1, € - 1 CYCLE 820°C - VACUUM 1, € - 1 CYCLE 820°C - PP ARGON - 1 CYCLE 1040°C - VACUUM - 1 CYCLE 1040°C - PP ARGON - 1 CYCLE 1040°C - PP H2 - EMBALLAGE SOUS AZOTE P= Pièce - F= Forfait - K= Kilo - C=Cent - M=Mille - Fe=Fournée * poids calculé à vérifier Le devis a été réalisé selon vos exigences mentionnées sur notre devis, toute exigence complémentaire fera l'objet d'une analyse et d'un éventuel avenant. Offre basée sur une Quantité totale de pièces. Observations: Impératif : joindre une copie de ce devis à votre commande ou en rappeler la référence. Merci Toute commande reçue sans numéro de devis sera chiffrée au tarif approprié. Traitement réalisé en notre usine de Villaz : Votre contact :Monsieur SIBUE Vincent VALIDITE : 3 MOIS P.V. ou CERTIFICAT DE CONFORMITE : 25,00 € HT DIAGRAMME : 38,00 € HT TRANSPORT A / R : EN SUS CONDITIONS DE REGLEMENT : 30 jours nets CONTRIBUTION A LA LUTTE POUR LA DEFENSE DE L'ENVIRONNEMENT DURABLE : 0,85% CONDITIONNEMENT : 2% TAXE CETIM : 0,1 % FACTURATION HEBDOMADAIRE Prix remis sous réserve d'essais, sur présérie significative, pour validation. La garantie de certaines caractéristiques peut nécessiter un contrôle destructif. Le redressage et la protection sont facturés en sus au temps passé, sauf cotation précisée. CONDITIONS GENERALES DE VENTES : Ce devis est accompagné de nos Conditions Générales de Vente en page 2 Restant à votre disposition, nous vous prions d'agréer, Madame, Monsieur, nos salutations distinguées. Raymond SAEZ Tél : Portable : Ingénieur d'affaires en Brasage et Soudage FE CO XX 03.XX IM 01 Ind 8

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27 Thank you for your attention!
AKNOWLEDGEMENTS to : Serge Lebet Thodoros Katopodis Margarita Saifoulina Maria Filippova Alexandre Samoshkin Germana Riddone Nick Gazis Thank you for your attention!


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