1. Substrate-Paddle-Base Peter Cooke

2. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR2 Substrate- Paddle-Base Substrate Production Paddle – Base – Feet Component Production

3. LHCb Substrate

4. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR4 LHCb Substrate Production Substrate Dimensions Materials and preparation Lay-up Inspection and Packaging Recommended Curing Instructions Summary

5. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR5 Substrate Dimensions Carbon Fibre 177 x 123mm TPG 169 x 115mm 4mm Carbon Fibre frame suppounding TPG

6. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR6 Materials Preparation TPG 400um TPG board cut to 169 x 115mm Abrade both sides with course emery paper Cleaned and degreased with alcohol Left to dry

7. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR7 Preparation Carbon Fibre Supplier; Amber Composites UK Carbon fibre Pre-preg 120 gm plain weave, epoxy resin impregnated Cut to size 177 x 123mm 2 Pieces – weave direction 0 – 90 deg 2 Pieces – weave direction +/- 45 deg Pre-preg approximate cured thickness 0.125mm per layer

8. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR8 Lay-up Procedure Release film applied to flat steel plate 1 st layer 0 – 90 deg on flat plate 2 nd layer +/- 45 deg on top TPG placed centrally on 2 nd layer 4mm strips of pre-preg surrounding TPG – 3 layers with orientation of fibres balanced 3 rd layer +/- 45 deg placed over previous 4 th layer 0 – 90 deg to complete

9. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR9 Lay-up continued RED 0 – 90 Deg BLUE +/- 45 Deg GREY TPG

10. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR10 Inspection & Packaging Visual Inspection Measurement – Micrometer/Smartscope Substrates have release film applied to each face to protect resin 10 substrates are sandwiched together between two 6mm thick aluminium plates Surrounded in foam and packed in carboard box Shipped off to Stevenage Circuits

11. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR11 Recommended Cure Amber Composites Fibre; T300 Resin E722.02 45% RW Increase temp. to 120 C @ 3 C/ min Increase pressure to 90 psi Hold for 1 hour Cool to 60 C before releasing pressure

12. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR12

13. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR13 Summary Have all material to produce up to 70 substrates Carbon Fibre stored in freezer @ -18 C TPG stored in locked cupboard Can produce 10 per week

14. LHCb Paddle/Base Components

15. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR15 Paddle/Base Assembly

16. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR16 Component Production Base and Feet Manufacture Paddle Fabrication Paddle cure Inspection

17. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR17 Base and Feet Manufacture Base – Cut from solid sheet of carbon fibre and machined in-house. Invar feet – CNC Wire Eroded in-house to guarantee accuracy. Spigot on right foot tolerance 0.000 to –0.008

18. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR18 Paddle Fabrication Material; Pre-preg ACG VTM264/CF0300-42%RW 200 gram 2 x 2 Twill (Stored–18deg C) Female mould tool CNC machined and hand finished in two halves. Dowelled and fastened together during lay-up Tool treated with PTFE release solution and buffed to a gloss finish

19. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR19

20. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR20

21. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR21 Paddle Lay-up Carbon fibre cut to templates, 2 layers per face. 1 @ 0/90 deg and 1@ +/-45 deg Apply fibre to each face, 0/90 then +/-45 Final thickness over major area of paddle 0.5mm Rear face – fibre flush to tool surface Front face – overlapping tool face 6 – 2mm along length 3 x 12mm wide strips added to each face at the topmost area of the tool.

22. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR22

23. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR23 Paddle Lay-up (cont) Add release film and bleed ply fabric to the exposed fibre Add a strip of breather fabric to each side Make vacuum bag and fit into front side of tool Place rear side of tool over dowels on the top and fasten into place Place assembly into large vacuum bag and seal inner to outer bags

24. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR24 Paddle Cure In autoclave Apply vacuum Heat to 65 deg C at 0.5 deg C/ minute At 65 deg C apply 90 psi Hold for 16 hours Cool, release pressure and vacuum De-mould the part

25. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR25

26. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR26

27. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR27 Parts Inspection Visual inspection – Inside and Out Fitted to drilling jig

28. Peter Cooke 28 Feb - 1 March 2006 - VELO PRR28 Summary We have enough carbon fibre stored in freezer to produce 80 paddles Carbon Fibre Bases ready Invar Feet ready