SCT BARREL PAR - RAL May 2003 Status of Barrel Mechanical Structures - Cylinder manufacture - Bracket and small components manufacture - Dry assembly - Work on barrels before shipment to RAL - Open issues - Transport / Logistics - Schedule Eric Perrin

1) Cylinder manufacture (by Astrium) The four SCT cylinders have been delivered from Astrium between Oct 2002 and March Today B3 is at RAL, B6, B5 and B4 at UNI-GE. Several problems encountered during manufacture introduced delays. - Machining - A few pads were de-bonded during machining - Understanding the Metrology

B4 bracket mounting hole metrology

B5 bracket mounting hole metrology (Problems with holes precision)

Module to structure interface Module are fastened in three points Tilt angle is :11° for B3 & B ° for B5 & B6 2 main points 3rd mounting point

Brackets and small components production. All together there are > small - special - components to be produced, some are the sames for the 4 barrels, some are specific to one type of barrel and even to upper or lower modules. The brackets shells are time consuming to produce and are on the critical path. Laminate by Composite Design Machining by UNI-GE

Brackets for B3 - A lot of problems encountered during shell manufacturing. Cyanate-ester proved more tricky than epoxy to use for this application. The company also had autoclave problems for a few batches. This was in some cases only discovered late, in fact during machining. Approx 150 B3 brackets (out of ~400) have been rejected. - The new prepreg received has improved things Bracket shells situation : B3: Done B6: Expected Mid June B5: To be ordered B4: To be ordered

Quite late, we decided to Parylene coat the shells. This works well but require a lot of extra preparation work. Bracket machining

All Small components for the four barrels have been ordered and delivered except: - Dogleg clip, first batch (800-for B3) received, production release for the next batches (4000 pieces) to be given by RAL. - PEI module centering bush, first batch of 200 delivered. Change in tolerance identified. Production release to be given after mounting trial by Oxford. - Module clip, still need to be finalized, contact have been made with industry for the identification of an appropriate insulating coating. Tests needed. - 3rd point Clip, Barrel specific item: done for B3 Drawings just finished for the three other barrels. Quotes in May. Production June July.

Work on cylinders before shipment to RAL « Dirty work » - Counterdrilling of outer facing underneath pads, done for B3 - Check/adjust mountability of brackets on pads, done for B3 - Evtl re-bonding of a PEEK pad, done on B3. - Surface preparation for bonding FSI system. - Some finishing touches B3 & B6 at Geneva

Dry assembly - B3 was fastened with interlinks into B6, all screws could be fitted and all dowel pins were mounted by hand (H7 - g6 tolerances). - B6 supported by temporary supports fastened into the bearing mounting points. - Work to be redon with B5 and B4.

« Clean Work » - Cleaning cylinder - Isopropanol, vacuum cleaner, Q-tips etc… - Electrical continuity tests - Mount brackets - all screws tightened with torque controlled screwdrivers (brackets have el-isolated from cylinder). - Rough geometrical check. - Visual inspection - Pack for shipment B3 ready for packing - equipped with shocklog recorder

Open issues Interlinks, B6 supports, junction parts to Pixel detector and TRT rails, penetrations through Thermal Enclosure are still conceptual. A crash programme on these items is needed in the next two months Interfaces with Pixels: - Pixel Support still conceptual (Pixel Tube passed PRR. Induced loads into SCT for most load cases have been reduced by use of flexures. Loads induced by Pixel services still unknown). Interface with TRT: - Rails and rail extensions to be finalised.

Transport / Logistics - Each barrel travel from UNI-GE/CERN to RAL in original wooden box. - From RAL to Oxford, special inner /outer container system will be used.

Air transport to Japan - Only way to have temperature controlled is to use a special Envirotainer. - The largest Envirotainer his is too small to accept B4 in its inner container. - Maybe this Envirotainer can be used if B4 would be contained in a simpler and smaller spl frame. This requires extra handling at RAL, at KEK and at CERN. More work needed.

Schedule for delivery of barrels to RAL This is mainly driven by Bracket production and assembly Bracket shells B3: Done B6: Production started, aim to complete Mid June B5: Still to be ordered, expected Mid July B4: To be ordered, expected Mid August Barrels to RAL B6: End of July B5: End of August B4: End of September