Activity report from LNF Panels Soldering tests Production site and tooling status WPC miscellanea (+7 cm layout, cathode costs, aging tests)

Panels As discussed in our last meeting 2 main activities on panels 1)Produce a batch (6-10) with same technique and few upgrades 2)Prepare the mould for preseries production (Dec-Jan) This work is ongoing (5 new panels this week) In the meantime we got 6 new (small, 35x25 cm2) panels from the new company contacted at the end of September (Internormal, Chieti, 250 km east of Rome) Internormal is a mid-size company (20-30 employees) with a production of large size polyurethane elements (eg. train seats) and several different injection machines, thermal stabilizing circuits and experience in large productions. Controlled areas also available for “clean” productions

The 6 panels show good quality, both in term of planarity and foam quality. They look also very clean. The panels were kept in the mould 20’-40’ As example, the weight of the panel is controlled at 3%. Noticeably, the result achieved with no interactions with the company ! This test witnesses very good expertise in mould design and in foam technique Smaller panels could be obtained without cut from larger moulds We also got a preliminary quotation for a production of 30 panels/day with 2 moulds This new fact suggested us to shorten the test we are doing, bring back to LNF the mould, speedup the mechanical upgrade of it and send to Internormal for a production test

Soldering tests with the machine after mechanical upgrades

Parameters of the tests performed last week Laser power (range 50-80% of 20 W) Soldering speed (and sequence of movements). Now 2 s / wire Speed of the soldering wire feeder Soldering on gold plated pads “less” easy (more power needed, or maybe, slower). Past tests all performed on tin plated printed boards Even in this case, very good quality, fast, clean (on L-head#1) On the L-head#2, erratic distribution of tin, more polluted, probably due to different soldering wire feeding (under check and correction) Safe operation between two pads (final check with longer HV bars) Rescan with laser can correct local imperfections Final goal: optimize parameters to reduce power (cleaner soldering)

Site and tooling status Wiring machine : combs ordered and mechanics under completion Wire tension measurement : drawings ready, material procurement underway (Rome 1). Ready by Feb. Panel planarity check tool : Rome 2 is taking care of it HV bars gluing tool : Firenze is taking care of the test of a new (simpler) solution LNF clean room : room completed, waiting for filters and conditioning (bid had to be repeated, ready by Jan)

HV bars and Cathodes Semi final cost quotation (after a long discussion) Tooling for large cathodes production : 100 keuro Total cost estimate in our CORE : 870 ksf 4 configurations considered 1.R4 copper, rest 1 cathode + 1 ground g.plated : 880 ksf 2.R4 copper, rest 2 cathodes g.plated : 970 ksf 3.M1 1 cathode + 1 ground g.plated, R4 copper, rest 1 cathode + 1 ground g.plated : 945 ksf 4.M1 2 cathodes g.plated, R4 copper, rest double cathode g.plated : 1040 ksf Synergies with CSC-ALICE ? Under consideration

Aging tests December, 16-20, one week to study ENEA-Casaccia Co 60 irradiation site (free of charge) and to prepare the real one 2 small chambers and 2 GEMs will be installed at different distances from the source to find suitable locations Real aging test 30 days at 100 nA/cm = 0.25 C/cm equivalent to (if G=10**5) 2.5 y of LHCb in M1R3 or 5 y in M2R1 Can we go to higher current densities ? Gas heating due to high rate (W=VI=3000 x 1 mA = 3 W / gap) ? True test in spring ? Final materials needed

+7 cm layout, available on LNF-LHCb web site, together with all other numbers

Conclusions Soldering tests with final setup show no surprises An industrial production seems now feasible. Struggling against required precision and systematic effects Tooling and site (LNF) : should be ok for June start ! Warning : with lack of decisions (or continuously changing layout) no material will be available by June Big bids (Panels, Cathodes, HV bars, Wire) = long administrative time (at least 6 months)