1. Pierre Delebecque Cooling – upgrade 2012 May 31 st 1 Inner detector upgrade / IBL Activities on cooling circuits @ LAPP LAPP team Jacky Ballansat, Patrick Baudin, Pierre-Yves David, Pierre Delebecque, Sabine Elles, Mohamed El Kacimi, Nicolas Massol, Thibaut Rambure, Jean Tassan, Theodore Todorov, Tamer Yildizkaya

2. Pierre Delebecque Cooling – upgrade 2012 May 31 st 2 Beam Pipe Manifold connexion Ceramic PP0 brazed sleeve OUTLET SS ID 1.5-OD2.5 IST INLET Stave LAPP Fitting 1.7mm Ti ID 1.5-OD1.7 Ti ID 2.0-OD2.2 LAPP Fitting 2.2mm SS ID 2.0-OD3.0 1 – IBL Cooling lines Layout pp1-pp0

3. Pierre Delebecque Cooling – upgrade 2012 May 31 st 3 Specifications 2 –Fittings Small fitting, less than  10 mm : –To minimize budget material –To fit inside a limited volume Maximum leak rate (He) : 10 -8 mbar.l.s-1 @ 20bar Pressure (bar): Radiation level : up to 1000 Mrad Working temperature : mini -40 °C  maxi +20 °C Pipes dimensions : –Typical type I tubes : 1.5 and 2 mm ID, 0.1mm wall thickness Pipe material : Titanium T40

4. Pierre Delebecque Cooling – upgrade 2012 May 31 st 4 Context 2 –Fittings Current developments based on IBL context (but upgrade is the next step) Fittings will be used @ PP1 (end of IST) Developments for Upgrade …and other experiments

5. Pierre Delebecque Cooling – upgrade 2012 May 31 st 5 3 –Fittings Fittings evolution summary

6. Pierre Delebecque Cooling – upgrade 2012 May 31 st 6 Fittings evolution summary (Baseline) 3 –Fittings Material Titanium grade 2 and 4 : hardness to low Titanium grade 5 (TA6V) : same hardness as Stainless steel use for commercial fittings Shape Cone/cone : “random” results Cone/toroid : good results but design sensitive to misalignment Cone/sphere Gliding surface treatment PVD carbon tungsten : good to prevent “metal chips” (good hard wearing) Graphite : should be as good as MOS2 but same results as “no treatment” ??? MOS2 ( special attention to prevent treatment migration on cone and sphere) Leak tightness surfaces Cone raw from machining / sphere polished

7. Pierre Delebecque Cooling – upgrade 2012 May 31 st 7 Tests - prototypes 2 –Fittings Prototypes “base line type” manufactured and tested 16 prototypes made @ LAPP 50 prototypes made in the industry Tests motivations Comparison between LAPP and industrial production (similar results) Influence of the polishing Comparison MOS2, graphite, PVD (tests on fittings + specific tests) Influence of the heating on material characteristics ( conclusion= decreasing of the hardness !! -> no brazing !!! (for Titanium and stainless steel) Prototypes on other devices Stainless steel on cooling loop prototypes TA6V on first IBL stave 0 Other developments Special tooling to prevent rotation and to apply the required torque : first prototypes

8. Pierre Delebecque Cooling – upgrade 2012 May 31 st 8 2 –Fittings Issue Connection between samples and test device seemed not as good as the fitting itself Difficulties to validate the samples if there were other leaks No problems @ room temperature but leaks appeared @ -40 °C (He 20 bars) Actions He test of the vacuum seals (room temperature and cold) : seemed OK Different type of materials for seals and flanges and shapes (and glues) have been tested Take into account the expansion coefficients of the materials Performed simulations Conclusion Leaks appear on elastomer vaccum seals @ a precise (cold) temperature. Elastomer seal replaced by an helicoflex (aluminium + spring) Hoped the problem would have been solved sooner Better sample/flange connexion New titanium seal developed Needs “high torque level (30 N.m) Leak tightness studies

9. Pierre Delebecque Cooling – upgrade 2012 May 31 st 9 2 –Fittings Leak tightness studies New Sample flange assembly

10. Pierre Delebecque Cooling – upgrade 2012 May 31 st 10 2 –Fittings Tests of proto stave have been performed @ LAPP Up to 50 temperature (-40 to +50 °C) and pressure cycles (5 to 60 bars) LAPP fittings (  10 mm) + swagelok mounted on the stave 150 bars hydraulic pressure test CO2 cooling tests

11. Pierre Delebecque Cooling – upgrade 2012 May 31 st 11 2 –Fittings New tests Last tests to be done on 18  10mm fittings Leak tests on new  8mm fitting (1 st standard test OK (1.510 -8 mbar.l.s-1 @ 20bar @ -50 °C) Developments Tightening tool : Next steps  8mm design

12. Pierre Delebecque Cooling – upgrade 2012 May 31 st 12 3 –EB welding 4x10 samples welded Good general results, no leak @ 1bar He (Techmeta) Small amount of material inside the pipe More metallographic analysis results from CERN in the future Leak test :1 st standard test OK (1.810 -8 mbar.l.s-1 @ 20bar @ -50 °C) Metallographic analysis from Techmeta ( 1.5mm and 2 mm ID pipes)

13. Pierre Delebecque Cooling – upgrade 2012 May 31 st 13 4 –Electrical break Baseline solution : electrical break independent from the fitting Placed on the “dismountable” side Stainless steel pipe EB welded on a “kovar” cover Titanium pipe EB welded on a titanium cover Ceramic brazed on the 2 covers Material used for brazing can contain silver Covers have to be machined to produce prototypes Alternative solution : electrical break included in the fitting One part of the fitting is made of ceramic (male or female) or both The ceramic is placed on the dismountable side More compact than the baseline solution First tests : no good results -> elements back to the manufacturer for polishing Improvement: titanium coating on the contact surfaces. Stainless steel pipe Titanium pipe kovar cover Titanium cover Ceramic

14. Pierre Delebecque Cooling – upgrade 2012 May 31 st 14 5 –Quality Goals  Made by leak tightness and industrial developments experts  Survey of the design, the tests and prototypes, the methodology, the QA  Last step before production First main recommendations  Improve the qualification of the test devices  Be more rigorous to analyse the “untypical” results  Check if a fitting machined at the limit of the tolerances fit the specifications  Perform geometrical and dimensional measurements  Better define the risks of pollution and damage  Better define the backup solutions in the case of trouble (risk analysis)  Work on the production procedure and be sure the sensible parameters are recorded Next action  Production quality management : need a new contract and €€ CETIM audit

15. Pierre Delebecque Cooling – upgrade 2012 May 31 st 15 Summary  10mm Fittings seem OK  8mm Fittings have to be validated EB welding : last tests to perform but we are confident Electrical break : Base line solution to be tested – integrated solution seems more tricky Cooling lines production : preparation in work / help of CETIM to manage the quality