1. 6/8/2006 Particle Physics Division Technical Centers 1 Vacuum Deposition Thin Film Coatings Facility at Lab 7 Eileen Hahn

2. 6/8/2006 Particle Physics Division Technical Centers 2 Services Offered Optical fiber and connector polishing Fiber splicing Evaporated and sputtered coatings, especially fiber mirroring Cleaning and bake-out for UHV parts High temperature vacuum furnace (1200 C) -hydrogen degassing of SRF cavities RGA and out-gassing studies Plasma etching

3. 6/8/2006 Particle Physics Division Technical Centers 3 High Output Production History of Optical Fiber Polishing & Mirroring CDF Plug and Muon Tracker CMS HCAL CREAM D0 Central Fiber Tracker, VLPC Production, ICD, Forward Pre-Shower & Forward Proton Detectors NASA-GLAST PHENIX STAR-EMC Fiber barrel & End cap  Polished >1,000,000 fibers  Mirrored >500,000 fibers

4. 6/8/2006 Particle Physics Division Technical Centers 4 Polish and Mirror Processing of Optic Fibers “Ice Polishing” Quality Control Preparation for Mirroring Sputter Deposition in Vacuum Optional UV epoxy coating of mirrored ends Transport Packaging

5. 6/8/2006 Particle Physics Division Technical Centers 5 “Ice Polishing” of Optical Fibers 2 programmable diamond polishers built at Fermilab specially engineered to reduce/eliminate vibration Frozen water clamps fibers eliminating chatter and lubricates allowing for high rpm and slow feed recipe for high quality polish Fabricate special hex fixtures to hold fiber bundles normal to cut  Individual Fibers ranging from 0.35mm to 2mm diameters  Round and square cross section fibers  Setup for fiber lengths from 5cm to 10m Rate of production is dependent on diameter

6. 6/8/2006 Particle Physics Division Technical Centers 6 Quality Controls Daily testing procedure of polishing results Attention to machine maintenance Log keeping Visual inspection of fiber polish under magnification Monitoring of sputter process, tracking identification and visual inspection Reflectivity testing has been handled by the experimenters –Reflectivty rates have ranged from 80% to 90% consistently

7. 6/8/2006 Particle Physics Division Technical Centers 7 Prep for Mirroring of Optical Fiber ends Amber room lights for light sensitive fibers (such as 3HF) Experienced handling and cleaning of delicate fibers All fibers handled with CR100 rated gloves

8. 6/8/2006 Particle Physics Division Technical Centers 8 Sputter Deposition System for Aluminizing fiber ends

9. 6/8/2006 Particle Physics Division Technical Centers 9 Fiber Mirroring Sputter Process 2 vacuum systems specifically built and dedicated to optical fiber sputtering Varying diameters & lengths can be mirrored - systems were designed to accommodate production lengths of 2.5 meters. Auxiliary extension will handle 3.5 meter long fibers Sputter load dependent on diameter - typically 500 to 2000 fibers per pump down per unit 99.999% chemically pure aluminum target Very pure argon gas “Sputtering Grade” used 3000 Angstrom thick coating monitored with oscillating quartz crystal sensor Magnetron sputtering gun driven by DC power supply

10. 6/8/2006 Particle Physics Division Technical Centers 10 Summary We have been providing this service over the last 15 years Supporting  FNAL experiments  University R&D  DOE and International Facilities On time and on budget!!