1. M. Gilchriese Status Report Sectors, Rings, Frame December 2002

2. M. Gilchriese 2 Sectors Since the Last Pixel Week Laser welding of about 40 sector tubes to fittings was completed with about 90% yield for two good fittings on tube. One sector fabricated for initial system tests. But recognition that fault pressure in evaporative cooling system may be about 16 bar(abs), much greater than we had assumed before. Extensive testing of baseline sector tubes(aluminum 1060) and work hardening of same “Destructive” testing of sector made with 1060 tubes to 16 bar(abs) Extensive testing of stronger tubes(aluminum 3003) and work hardening of same. Fabrication of 3003 samples to test laser welding to existing coolant fittings. Laser welding ???

3. M. Gilchriese 3 Aluminum1060 Tubes

4. M. Gilchriese 4 Tube Deflection Tests Measure tube deflections under pressure, with and without work hardening. Also some testing of bent sector tubes. Measure deflection Under pressure

5. M. Gilchriese 5 Test Sector to 16 bar(abs)

6. M. Gilchriese 6 Summary of Deflections 1060 tubes only 3003 tubes only Sector with 1060 tube

7. M. Gilchriese 7 Sector(1060 tube) after 16 bar No catastrophic failure. Tube on edges expands inelastically. Most of region not affected. Sector construction prevents tube from expanding except on edges.

8. M. Gilchriese 8 Other Pressure Tests We have tested about 10 samples of the fittings welded to the sector tubes up to 20 bar without any evidence for leaks => fittings OK. We have also tested one welded tube(1060) with laser welded fittings to 20 bar and no leaks were found => welding probably OK.

9. M. Gilchriese 9 Sectors Conclusion Sectors with 1060 tubes might survive up to 16 bar but would have to test more sectors and with silicon(does silicon break?). Issue is potential for damage to other sectors. If we go to work hardened 3003(we do the hardening by internal(up to 20 bar) and external pressure to flatten), then for sure no problems at 16 bar(or even higher). This is the safe way to go. We have 3003 tubes on hand although they are a few mm shorter. Bending of these tubes started. Laser welding ?? Going to 3003 will cause some delay and some extra cost(for the additional laser welding). But looks like we can still meet schedule for delivery of sectors when production modules ready. Sectors for system tests not affected – will use 1060 tubes.

10. M. Gilchriese 10 Reminder Disk Rings Endplate Endcone Disk Frame Barrel Frame Disk Ring Mounts Disk Sectors

11. M. Gilchriese 11 Disk Ring Fabrication Complete

12. M. Gilchriese 12 Dry Fit of 1 st Disk Frame Section December 5, 2002

13. M. Gilchriese 13 Dry Fit of 1 st Endcone December 5, 2002

14. M. Gilchriese 14 Global Support Status No significant problems so far. Bonding of 1 st disk section this week, followed by 1 st endcone before Xmas. Most of parts for other sections ready or ready very soon. Dry fit -> bond -> inspect other sections starting in January. We remain on track to complete the fabrication by April 2003.

15. M. Gilchriese 15 Miscellaneous Items Custom “bolts” for mounting disk sectors to rings. –Delayed by work on sector tubes but will order in January Disk ring mounts –Fabrication underway for delivery by mid-January Tooling for drilling disk frames and inserting rings –Prototype completed long ago(with larger frame size) –Update delayed by work on PP1(and other parts of ATLAS). –Also realize will take some time to (re)survey rings with actual mounts. –Will be February before we start on drilling end section of frames.

16. M. Gilchriese 16 Welding of Transition Pieces Insertion of cables at PP0 greatly aided(only possible?) by making transition from 8mm to 4mm tubing outboard(larger Z) of PP0 connectors. 4mm pipes pass between connectors. Laser welded various types of transition pieces to find best.