ATLAS UK-Upgrade WP7 LMT Automated Manipulation Testing Manipulation testing objectives The mechanics of the system Applications Joining Technologies Types of joining explored Feedback from commercial experts Where next? Tracker Upgrade Plenary - Coseners House 8th July ‘08 WP7 Engineering - Richard French Richard French

Objectives To demonstrate robustness by Pinpoint failure mechanisms Automated manipulation of the laminated and un-laminated areas of the LMT. Manipulation of the soldered area if required. Automated cycling of any chosen connectors. Strongly advise to ignore manufactures life expectations as we somehow manage to do something differently. (Not heavy handed!) Pinpoint failure mechanisms Electrical testing during manipulation, initially resurrect the “snake testing” principle to give failure feedback to system. On event of failure examine specific line manually, DVM+Microscope. Learn before the tapes actually go on a detector! R&D during the final assemble stages of detector build is not acceptable. We should (in theory) have enough experience to do this throughly. 31/12/2018 © The University of Sheffield

The manipulation jig Flexible control system 4 manipulation tests to begin with 1, Connector cycling test 2, 180° longitudinal bend test R=3.0mm 3, 90° longitudinal bend test R=2.5mm 4, 5° lateral twist test (free space, no guide) Pneumatic cylinder actuation 1.3 to 10.0 Bar operating pressure Double acting piston -30°C to + 80°C operation (thermal cycling?) Can operate up to 10 cycles per second reliably. Interchangeable test heads for cylinder Different dimensions and flavours of tapes, new head – same piston Initially R2.5mm for bend tests but can quickly alter to whatever we find we need. Different types of connectors Again, a flexible system to allow for different connectors. Flexible control system Using a programmable FEC via CPX terminal the system can be expanded to ~20 cylinder system Price of additional cylinders to expand system is very low ~£50 inc ancillaries. Feedback loops provided by 0-10Vdc CPX card = tape trace/track fails, system stops and records cycle count. Really simple and in theory ultra-reliable. Switch on and leave running unattended if required.

Applications On Barrel, Supermodule or Stave local services BA module to PP1 and EC module to PPF1 Interfaces / bus cables Simple Cu Kapton interfaces needed anywhere Could use to bend fibre optic ribbons if needed. Can test any cables used in cryostat region. Any application with a bending requirement with up to 68N of force over 50mm. 31/12/2018 © The University of Sheffield

Joining Technologies Desirable connector-less systems explored for tube-tube and tube-block using variants of standard processes; TIG Welding Laser Welding Diffusion bonding hot and cold. Autogenous processes remove operator error and increase yield. TIG – Orbital and Micro Orbital Portable, easy and high yield. 2mm OD x 0.3mm on the reliable limit of this technology Laser and pulsed laser Far from portable! Fantastic weld results with virtually no cleaning required Exceptionally high yield but equipment expensive so would look for commercial involvement. Diffusion bonding hot & cold. Not recommended for small bore thin wall tubing as debris is created by the bonding process. Exceptionally difficult to remove and drops of during life of pipe. 31/12/2018 © The University of Sheffield

Experts feedback Orbital Fabriactions Ltd TWI (The Welding Institute) Like our base line materials choices of 316L and suggest Autogenous process such as Orbital or Laser. 2.0 OD is on the limit of current Orbital welding technology with thin wall 316L tube. Laser welding is potentially OK. Surprised we have not considered Titanium tubing! The ATLAS tracker upgrade specs, fall in a dead split between dedicated areas at TWI. Semi-conductor type joining with off-shore applications and corrosion requirements! Possible grant available through TWI South Yorkshire and Yorkshire Forward. Exploring further. Orbital Fabriactions Ltd Have had a play with our 316L 2.0 OD tubing and can not make a weld to BS EN28Y77, BS EN2877, ASME IX and JIS B8243 with sufficient yield. Welding OD >3.175mm (3/16”) is possible in thin wall Can not weld Aluminium and will not Can weld CuNi with Orbital head. Can also weld CuNi to S/S. Not followed up as yet. 31/12/2018 © The University of Sheffield

Where next? Pursue TWI/YF funding for trails or review. Get test pieces and feedback from OrbFab Ltd Explore Titanium tubing and understand the multitude of alloyed grades and applications. Giving up on Aluminium as very time consuming. An optimum set of numbers for the orbital process on 316L S/S must be quantified. Power control / OD / Wall thickness = Weld quality. The same should be applicable to Ti alloys. Locate experts at CERN and facilities we can tap into. Bring Engineering Materials Dept in for metallurgy on weld, student project? 31/12/2018 © The University of Sheffield