1. 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

2. 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.
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© The University of Sheffield

3. 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.

4. 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

5. 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

6. 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.
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© The University of Sheffield

7. 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