1. B02 - 4 [OT - Mechanics & Cooling] 402.02.04.05 Stefan Gruenendahl February 2, 2016 S.Grünendahl, 2016 February 2 Director's Review -- OT: Mechanics & Cooling

2.  Overview  Key Features & Technical Challenges  Initial Design & Prototype Work  Summary Outline S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling

3.  The US will design and build the central (non-tilted) portion of the Phase 2 TBPS, consisting of three layers of PS modules, with lengths around 300mm (L1) to 650mm (L3).  Phase 1 FPIX experience & initial estimates indicate that mechanical support and thermal management are solvable problems. We are investigating a carbon fiber/carbon foam sandwich plank with embedded CO2 cooling.  Initial designs for the module mechanical & cooling support planks, the plank support rings and cooling line interfacing exist.  Engineering and technical support at FNAL has been identified.  We are collaborating closely with CERN engineering for overall mechanical and services integration.  The first round of thermal + gravitational distortion FEAs have been done, and results have been used to design the next thermal prototype plank, which is currently under construction. Overview S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling

4. Quarter view of the TBPS Phase 2 Tracker Barrel Pixel Strip Detector (TBPS) Director's Review -- OT: Mechanics & CoolingS.Grünendahl, 2016 February 2 US contribution:  Modules  Complete central part of TBPS detector

5.  Synergies with FPIX Phase 1 upgrade  Project group overlap, experience with CO 2 cooling  Existing test system  Experience with mechanical and thermal design and FEA modeling (PS module thermal mounting same as FPIX) allows estimation/extrapolation of basic CO 2 cooling parameters (power density, total power per cooling loop, flow requirements)  Material for the initial prototyping (carbon fiber, stainless tubing, some carbon foam) is at hand  Plank design for module support & cooling and thermal prototyping take advantage of the work done during the past 3 years for the Phase 2 ‘Long Barrel’ rod design & prototyping New challenges Power supplies and optical transceivers integrated into module TBPS layer structure closely couples flat barrel and tilted barrel Key Features of Mechanics & Cooling S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling

6.  Module & module interface design from CERN Module Support Structure (the ‘Plank’) Plank Assembly with Modules S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling

7.  Planks supported by rings; services routed in Z along ring support rods; the ring support rods also provide the mechanical integration with the tilted barrel sections. Integration & Plank Support S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling

8. Layer 1 of Central Flat PS Barrel Assembly F10049832 Central Barrel S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling

9. M2 inserts embedded (glued with CF facing on end faces) Plank Design Details  Layer 1 Plank Assembly F10047557 3 modules on top 4 modules on bottom 320mm(L) x 136mm(W) x 6.36mm(T) S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling

10. Titanium M2 inserts embedded (glued with cf facing on end faces) 0.18mm thick (3-ply) CF facing Aluminum M2 Socket Head Screws Removable Couplings SS Tubing OD 2.4mm 6mm thick C foam CF ‘C’ support channels Inner & Outer tubing assemblies offset 6 mm in Z Plank Design: Assembly View S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling

11. Removable Coupling for Tubing OD 2.413 mm Male Nut with 5 mm Hex; screw thread UNF #8-36 Gland Female Nut with 5 mm Hex; screw thread #8-36 Aluminum gasket Removable Coupling for Stainless Tubing 2.413 mm OD Mass in gHex 6.35mmHex 5.0 mm Gland0.08 Gasket0.007 Female Nut1.5360.705 Male Nut1.4811.162 Total, g3.1041.954 X36 Total, g111.74470.344 Note: Tubing at ends not shown CO 2 Coupler Design S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling Thread engagement

12. Foam, 3/8” thick G10 or aluminum inserts, 3/8” thick CF facing, 0.5mm thick Support Ring Design  End Ring Assembly F10052060 3 types of inserts embedded S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling

13.  Dummy module equipped with heaters and RTDs on plank prototype First Thermal Prototype Director's Review -- OT: Mechanics & CoolingS.Grünendahl, 2016 February 2 Two groups of ten RTDs across pixel sensor (through openings in plank and base plate) and strip sensor Plank has stainless tubing directly imbedded with TC 5022 thermal paste into grooves in carbon foam (no sealing) Pixel side temperature sensors

14.  Instrumented dummy PS module mounted on CO2 cooled plank prototype  Results: module itself is thermally well behaved (small ΔT pixel-strip); plank has insufficient coupling from carbon foam to stainless tubing (FEA needs 50% air bubbles at interface to reproduce ΔT) Results from First Thermal Prototype Director's Review -- OT: Mechanics & CoolingS.Grünendahl, 2016 February 2 FEA EXP

15.  Carbon fiber/Rohacell sandwich with carbon foam inserts around stainless steel cooling pipes  (Rohacell/Airex does not save much mass compared to all carbon foam – simplify structure by using all carbon foam as spacer)  Also modeled graphite, TPG (block) and PGS (thin sheet) inserts around tubing – only slightly better thermally, but more complicated to build Thermal FEA & Prototyping Director's Review -- OT: Mechanics & CoolingS.Grünendahl, 2016 February 2

16.  ~275mm length, 6mm thick carbon foam spacer with embedded 2.2mm stainless steel cooling tubes, 3-ply ultra high modulus carbon fiber sheets at top and bottom  Accommodates 3+2 PS modules  To be instrumented with one or more thermal dummy modules (coupled with phase change film), and simple heaters for the remaining module positions L1 Plank Prototype S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling

17. Tubing grooves filled with boron nitride loaded epoxy, re- machined to get smooth non-porous surface Stainless tubing embedded with thermal paste (a la FPIX) L1 Plank Prototype S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling

18. Summary S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling

19. The US is designing and building the Phase 2 Outer Tracker TBPS Central Section. FPIX experience and FEA modeling indicate that a design that meets mechanical and thermal requirements is possible. Tight integration with the titled barrel sections and close collaboration with CERN engineering is a key feature. We have a first iteration of a design for the plank itself, the plank support rings, and the cooling line interface. We are building the second thermal prototype. Summary S.Grünendahl, 2016 February 2Director's Review -- OT: Mechanics & Cooling