D. Greenfield CLRC1 UK-V End-cap Engineering 15 July 2003 Debbie Greenfield, RAL

D. Greenfield CLRC2 SCT End-cap Support Structures - Cylinder and Supports l Engineering Program (pre-manufacture) »Series of mechanical tests on laminates,sandwich panels and material qualification tests (eg. Fibre volume content) –All very good except problems with flatwise tensile strength in front and rear support sandwich panels –Will change from Ultem inserts to CF –Contractual negotiations underway »Mechanical tests on inserts - all exceeded requirements »CME and CTE - still awaiting some CME but all CTE and CME results so far exceed requirements l Production »Support Structure 1 was due for delivery July 2003 –Bare Support Cylinder manufactured –Will be a delay in the Front and Rear Supports

D. Greenfield CLRC3 Complete Support Cylinder

D. Greenfield CLRC4 l Produced CC/PEEK sandwich at RAL l Extensive testing of CC material inc. x-ray and thermal conductivity measurements at 3 institutes l Conclusion is that all the CC material is fine l Assembled blocks to middle and outer circuit and assembled middle circuit to CheapO l Placed initial order - enough for 2 disc 8s, 2 disc 9s and 1/4 DiscO. End-Cap Cooling Structures Main and Second Cooling Block Production

D. Greenfield CLRC5 l Order placed with industrial company for a pre-series of main wiggly sections for outers and middles. l Pipe from US turned out not to have been annealed l Trial anneal now done by Bodycote l Awaiting grain analysis results before annealing remainder l Second point and joining pieces made at RAL with no filler l Custom made pipe bender manufactured l Assembled in soldering jig at RAL End-Cap Disc Services Cooling Circuit Production

D. Greenfield CLRC6 Prototype Disc Assembly based on CheapO disc l All available pre-production services being assembled onto CheapO. Includes: »Complete middle and outer cooling circuits »Wiggly tapes »Opto harnesses »Grounding foils »Dummy hybrids l Still working on back – then need to do front l Very useful – need another couple of weeks l Still to do: »Thermal movement test »Delta P test (needs dummy thermal modules) »FSI component placement (needs modules)

D. Greenfield CLRC7

D. Greenfield CLRC8 Services from PPF0 to PPF1 l Design work has progressed well for the PPF1 electrical and cooling patch panels. l Prototypes have been installed on the mock-up at CERN. l Much work done to work out the LM tape lengths. l Design of cooling along the cylinder is on hold until the heat exchanger and capillaries are defined. This will soon be critical.

D. Greenfield CLRC9 SCT End-cap Support Structures - Discs l 4 bare discs produced in spec. and received at NIKHEF l All discs should be received by end Dec 2003 l Last 2 discs failed the Flatwise Tensile Test at PCI »YLA have tested the materials but not found contamination »PCI are now checking their procedures and processes »No new delivery date yet »This problem does not impact the disc-with-services schedule yet as 4 good discs are at NIKHEF

D. Greenfield CLRC10 SCT End-cap Support Structures - Discs l Disc 8A and 8C have had their apertures machined. »Start bonding inserts on Wed. l Discs 9C and 9A are being prepared for aperture machining. »9C will be started on Tue. 9A will follow soon after. l Then will start remachining the stiff base-plate on Mon 21 July. »More precision spheres (8 instead of 3) »16 adjustable supporting pins on the outer and 8 on the inner edge »expected to finish tooling Aug 8th »Then machine DiscO (2-3 weeks) »Then machine 9C l Expect to deliver disc 9C to RAL in the middle of Sept.

D. Greenfield CLRC11 Disc Schedule l First disc arrives at RAL mid-September l 4-5 weeks for services addition l Discs to Liverpool: »Disc 9 - mid October »Disc 8 - mid November »Disc 7 – beg January 2004

D. Greenfield CLRC12 Services Schedule l Tim Jones recently appointed as Services Coordinator  The objective is to do everything possible to ensure that Disk-9 gets to Liverpool by mid September as required for assembly.  Establish a list of all of the parts needed to produce (the first) discs to the point that they are available for module assembly.  Establish an agreed week by week schedule  Follow the progress of all parts and update me on a weekly basis  Where problems are encountered, help find solutions  Ensure that shipping arrangements are in place  All services should be ready for first disc but very tight