1. K.W. Glitza University of Wuppertal IBL Stave (Lessons for Upgrade)

2. Contents Stave Components Core Omega Pipe Tests Glue Distribution Thermal Qualification Leak and Pressure Tests (CTE Measurements) K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 2

3. 3 Function:Cooling Test Device PipeCF; OD = 3.0mm; Wall Thickness: 250 µm CoreK Foam Length120 mm IBL (Test) Stave

4. Carbon Foam Core Function: Heat transfer Material: Carbon Foam Cooling Pipe Function Boiling Channel Material: Ti, CF, Stainless steel Stiffener Structure Mechanical stability Carbon Foam Core Cooling Pipe Stiffener Structure 4K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 Through the Stave Assembly Overview Stave Components

5. Through the Stave Assembly Carbon Foam Core 5K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 Function Heat transfer structure; different shapes;depends from cooling pipe diameter Material Carbon foam with different densities (0.2- 0.5 g/cm³ ) and heat transfer conductivity (~30 – 150 Wm/K) (different brands) Responsible Wuppertal Length Up to 260 mm depends from the dimensions of raw material Status All production tools are ready, production steps well understood, more than 25 staves produced till now

6. Through the Stave Assembly Stiffener Structure 6K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 Function Stiffener structure Dimensions Up to 1000 mm Thickness: 300 µm Layup (0, 90, 0)° Material Fiber M 60 J Matrix EX -1515 Responsible IVW Status Ready

7. Through the Stave Assembly Omega Tool 7K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 Function „Omega“ Molding Dimensions 1000 x 25 x 25 (2 times) Material Graphite Production Wuppertal Responsible Wuppertal Status Ready

8. Through the Stave Assembly Boiling Channel 8K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 Function Cooling channel Dimensions Different diameters (2 – 4 mm) and different wall thickness (100-250 µm) Length: > 600 mm Material Ti (baseline) CF, stainless steel ? Production Ti, stainless steel: external company CF: IVW/Wuppertal Responsible CPPM/ Wuppertal Status Production steps well understood, many prototyp pipes produced

9. K.W. Glitza, University of Wuppertal9DESY, 20.4.2010 Through the Stave Assembly Carbon Fiber Braid Manufacturing Function Flexible tube braiding Dimensions Different diameters 2-4 mm >150 µm Material CF T 300 Production Barthels & Feldhoff Responsible Wuppertal Status Ready

10. tape wire braid inner teflon pipe sealing compound outer teflon pipe teflon vessel for resin aluminium mold 10K.W. Glitza, University of Wuppertal Through the Stave Assembly Carbon Fiber Pipe Manufacturing Function Flexible tube molding Dimensions Different diameters Material CF T 300 Braid Production Barthels & Feldhoff Responsible Wuppertal Status Ready

11. 0.5 mm 11 K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 Through the Stave Assembly Final Milling Function Flexible tube molding Tools High Speed CNC Milling Machine Responsible Wuppertal Status Ready

12. Function Final Milling of staves Dimensions 1000 x 50 x 20 Material Al Production Wuppertal Responsible Wuppertal Status ready Through the Stave Assembly Vacuum Clamping Tool 12K.W. Glitza, Uni Wuppertal AUW CERN, November 2010

13. 13 Through the Stave Assembly Cross Section „POCO- Foam“ Stave Function Glue Distribution Method X-Ray Tomography Responsible Wuppertal / IVW Status Ready

14. K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 14 Through the Stave Assembly Cross Section „K-Foam“ Stave Function Glue Distribution Method X-Ray Tomography Responsible Wuppertal/IVW Status Ready

15. K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 15 Function Cooling Tests with IR Camera Camera Type FLIR Responsible Wuppertal Status Ready Through the Stave Assembly Stave Testing

16. K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 16 Through the Stave Assembly Stave Testing Function Cooling Tests Set Up Camera Type FLIR Responsible Wuppertal Status Ready

17. K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 17 Function Cooling Tests Results Camera Type FLIR Responsible Wuppertal Status Ready Through the Stave Assembly Stave Testing

18. K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 Through the Stave Assembly Stave Leak Testing Function Multi High Pressure Leaktest Pressure Cycle Ramp up: 3 min to 150 bar Hold: 3 min at 150 bar Ramp down: 3 min to normal pressure Leak Test Cycle Apply He 30 / 60 / 120 sec Responsible Wuppertal Status Ready 30 sec He 120 sec He 60 sec He # pressure cycle

19. 19DESY, 20.4.2010K.W. Glitza, University of Wuppertal Through the Stave Assembly Stave Leak pressure Testing Function Leakrate Tester …….. High Pressure Saftey Box Responsible Wuppertal Status Ready

20. K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 20 Through the Stave Assembly CTE Measurement Set Up Function CTE Measurement Responsible Wuppertal Status Ready

21. Conclusion All major production and testing steps are well setteld at Wuppertal / IVW Our knowledge from the barrel shell production flows directly to the IBL Project K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 21

22. Back Up Slides K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 22

23. 23 23 CF Pipe Production Put the fabric into the vessel Put resin into the vessel Apply vacuum for degassing Close vacuum Pull the fabric into the mould Left device: vessel for fabric and resin Right device: mould for the pipe Working steps: K.W. Glitza, Uni Wuppertal AUW CERN, November 2010

24. 24 K.W. Glitza, Uni Wuppertal AUW CERN, November 2010 poco Through the Stave Assembly Cross section „POCO- Foam Stave Function Cooling Tests with IR Camera Camera Type FLIR Responsible Wuppertal Status Ready