S.Movchan Straw manufacturing and QC Dubna status Straw machines Assembly halls and tooling Presented by S.Movchan 1-May-18 S.Movchan Straw manufacturing and QC

Continuous straw fabrication Straw fabrication one by one Common view NEW machine Continuous straw fabrication Machine in operation Straw fabrication one by one ready 1-May-18 S.Movchan Straw manufacturing and QC 2

S.Movchan Straw manufacturing and QC Sonotrode + anvil 1-May-18 S.Movchan Straw manufacturing and QC 3

S.Movchan Straw manufacturing and QC Round shape formation by 4 rollers 1-May-18 S.Movchan Straw manufacturing and QC 4

Straw seam quality control 1-May-18 S.Movchan Straw manufacturing and QC 5

O-ring sample tensile test Seam quality control O-ring sample tensile test Visual check 1-May-18 S.Movchan Straw manufacturing and QC 6

Straw bar code + DB NA62 straw label: NA62TASTDU003525 NA62 – NA62 experiment TA – Tracker ST - straw DU– JINR, Dubna, Russia СE – CERN, Sefar, Swiss 003525 – straw serial # (000001-999999) 1-May-18 S.Movchan Straw manufacturing and QC 7

S.Movchan Straw manufacturing and QC Plans “Old” straw machine – READY for straw manufacture (needed tape from CERN) “NEW” straw machine: Tuning – September Tests and improvements - September (add on-line monitoring) Machine certification - end of September - pre-production series: N=100 pc, September (1-2 days) - send to CERN – 3 weeks - tests a lot of straws at CERN – 2 weeks - approval Start of straw manufacture – October 1-May-18 S.Movchan Straw manufacturing and QC 8

S.Movchan Straw manufacturing and QC Dubna 806 straws 1-May-18 S.Movchan Straw manufacturing and QC 9

Mass-production of 806 straws 1-May-18 S.Movchan Straw manufacturing and QC 10

Straw machine parameters after sonotrode reparation: (for straws with serial # ≥180) clean room: T=+(21±1) degree, H=(70±5)% some straw machine parameters: sonotrode angle: about 20 degree anvil diameter: 9.73 mm fixture diameter: 9.90 mm rollers position: right roller – 42/5 mm, left roller – 45/4 mm, gap – 18 mm dust removing from anvil: ON straw welding parameters: ultrasonic generator: clock F=(39750±50) Hz, P = (60÷100) a.u. => about 60% sonotrode head temperature: (27±1) degree (cooling ON) ultrasonic head pressure to tape: 210 g spool pretension: (150-200) g tape friction: (300÷400) g manufacture speed: 7 mm/sec 1-May-18 S.Movchan Straw manufacturing and QC 11

S.Movchan Straw manufacturing and QC 806 straws Tapes number Straw tubes A1-9 58 A1-11 73 A1-17 62 A1-10 84 A1-12 77 A1-8 93 A1-18 96 A1-4 (300 m) 98 A1-2 (300 m) 100 A1-7 (180 m) 65 806 ~90 straws/spool 1-May-18 S.Movchan Straw manufacturing and QC 12

S.Movchan Straw manufacturing and QC BLUE – straw start RED – straw end 806 straws Diameter Elongation Min = 1 mm Resistance Seam width 1-May-18 S.Movchan Straw manufacturing and QC 13

Load max F vs elongation dL: 3-D presentation Dubna 806 straws N Cut: F≤3.7 kG F (kG) dL(mm) 1-May-18 S.Movchan Straw manufacturing and QC Cut: dL≤1 mm 14

Zoom of BAD region near “0” 7 straws F=(0÷3.7) kG @ dL=(0÷1) mm 8 straws N F (kG) dL(mm) F=(3.7÷8) kG @ dL=(0÷1) mm F (kG) dL(mm) 1-May-18 S.Movchan Straw manufacturing and QC 15

dL > 1 mm @ Load max > 3.7 kG (for Dubna 806 straws) Blue – start straw Red – end straw dL=1 mm GOOD straws F=3.7 kG Total rejected straws N=28+7 = 35 straws Dubna straw rejection criteria: elongation dL ≤ 1 mm @ L ≤ 3.7 kG Total rejected straws: N = 35 straws (~ 4 %) and all good straws have elongation more than dL > 1 mm @ L > 3.7 kG 1-May-18 S.Movchan Straw manufacturing and QC 16

S.Movchan Straw manufacturing and QC Conclusion Both CERN and Dubna proposed criteria for straw rejection were tested on Dubna straws. Was shown that: - rejection criteria Load max F ≤ 3.7 kG (Strength=100 Mpa) is wrong: ~ 1 % of straws (7 straws out from 800) have elongation less than dL=1 mm - rejection criteria dL < 1 mm is correct. Number of rejected straws are N = 15 straws ( ~ 2 %) - combine criteria dL < 1 mm @ Load max F < 3.7 kG was tested too. Number of rejected straws are N = 35 straws ( ~ 4 %) 2 criteria and are tested and acceptable ------- Sefar straws: Straw sample elongation was not fixed during tensile test. So, straw rejection criteria can not be correctly tested. Elongation must be measure too. wrogn “soft” “hard” “soft” “hard” 1-May-18 S.Movchan Straw manufacturing and QC 17

S.Movchan Straw manufacturing and QC Conclusion Dubna 806 straws were manufactured (February-April 2011): ~ 20 straws/shift ~ 100 straws per spool (L=300 m). Efficiency of mylar tape used is about 90% Straw parameters: - diameter Dav = 9.78 mm - sample elongation dLav= 7.0 mm (o-ring 5 mm width tensile test) - visible ultrasonic track width Wav=0.725 mm - resistance Rav=61.8 Ohm (L=2600 mm) Straws rejection: - out of parameter specification ~ 0.7% ( 6 straws) - dL < 1 mm @ Load max F < 3.7 kG ~ 4.3% (35 straws) (and data lost for 34 straws) Dubna straw quality is adequate to NA62 requirements 1-May-18 S.Movchan Straw manufacturing and QC 18

S.Movchan Straw manufacturing and QC NA62 straw modules assembly site 1-May-18 S.Movchan Straw manufacturing and QC 19

S.Movchan Straw manufacturing and QC Bld. 217: common view Entrance gate 1-May-18 S.Movchan Straw manufacturing and QC 20

Straw module 3 assembly halls Frame assembly Vacuum test Wiring Connectivity Gas tightness HV test Assembly Area Cosmic test 1-May-18 S.Movchan Straw manufacturing and QC 21

S.Movchan Straw manufacturing and QC 3 halls Crane: 1.0 tone height ~ 4.5 m S ~ 150 m2 ( 9 x 16.6 m) Condition system S ~ 50 m2 ( 5.4 x 9 m) 1-May-18 S.Movchan Straw manufacturing and QC 22

Module assembly tooling Support frame + scaffolding Module tilter Delivery - 20 September 1-May-18 S.Movchan Straw manufacturing and QC 23

Vacuum pump and pressure sensors for module tests 1-May-18 S.Movchan Straw manufacturing and QC 24

S.Movchan Straw manufacturing and QC Conclusion Dubna NA62 straw modules assembly halls (S ~ 250 m2) – ready Module assembly tooling delivery - 20 September Module assembly tooling installation at hall – Sept.-Oct. 2011 Vacuum pump and pressure sensors – ok! Vacuum table – tender started Due to Module-0 assembly is in progress: Manufacture straw assembly tooling – postpone 1-May-18 S.Movchan Straw manufacturing and QC 25