1. WELDING TESTS & OTHERS ISSUES SUMMARY
WA104 PROJECT
NEUTRINO EXPERIMENTS
Jean-Pierre Brachet
Gilles Favre
Paula Freijedo
Didier Lombard
WA-104

2. INDEX INTRODUCTION PART 1: U-FRAME CORNER
STATUS OF THE WELDING CONFIGURATIONS
QUALITY LEVEL & NON-DESTRUCTIVE TEST (NDT)
STRATEGY FOR ASSEMBLY
TOOLING & MACHINING
PART 2: EXTRUDED CORNER ASSEMBLY
STATUS OF THE WELDING CONFIGURATIONS FOR THE CORNERS TO PANELS
TEST PIECE VALIDATION
QUALITY LEVEL
WELDING OF THE U-FRAME TO EXTRUDED CORNER
COMPONENTS DELIVERY
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WA-104

3. INTRODUCTION
The aim of this presentation is summarize and clarify some points related to the the different welding configurations and other issues for the Cold Cryostat WA104 in the frame of the Neutrino Experiment, in order to set up and qualify the best solution for manufacturing.
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4. STIFFENING FRAMES ALIGMENTS 1 To 5 – DRAWING: CEN104CR_0025
PART 2: EXTRUDED
CORNER
PART 1: FRAMES CORNER
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5. PART 1: U-FRAME CORNER
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6. 1- WELDING CONFIGURATIONS
2 configurations for the U-Frame corner ACCORDING TO THE DRAWING CEN104CR_0026:
Material: Aluminium EN AW-6082 T6
Thickness 20mm: MIG process (Details X1-X2-X5)
Thickness 10mm: TIG process (Detail X3)
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7. MIG PROCESS-20mm OF THICKNESS: Drawing for Welding Qualification
STATUS:
- Configuration and parameters of the pWPS: VALIDATED
- Welder qualification: On-going
- Welding Procedure Qualification (PQR): On-going
Values taken during the tensile test of the PQR:
Tensile strength Rm= 220 & 226 MPa
Yield strength Re=
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8. TIG PROCESS-10mm OF THICKNESS
Drawing for Welding Qualification
STATUS:
- Configuration and parameters of the pWPS: On-going
- Welding Procedure Qualification (PQR) &
Welder qualification: Next step
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9. 2- WELDING OF A REAL CORNER
Preliminary measurements of the Shrinkage on the real corner
+/- 0.1mm
+/- 0.15mm
Shringkage
Average
3.5mm
L=250mm
L=350mm
Gap 10mm
3- QUALITY LEVEL & NON-DESTRUCTIVE TEST DURING PRODUCTION
The required quality level for welds imperfections shall be level B according to the standard EN-ISO 10042:2005
NDT & sequence:
1º- Radiographic test or Ultrasonic examination (100%) NOTE: US requires FLATENNING on the welds
2º- Dye Penetrant NOTE: Defects reparation could be cause of CONTAMINATION
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10. 2 1 Cut and adjust the dimensions with the panel
3- STRATEGY FOR ASSEMBLY
Fabrication the U piece whole with both corners welded:
NOTE: The DIMENSION of the panel SHALL BE ensured - REPEATABLE
PROPOSAL: Fabrication of the piece in 2 parts with only 1 corner welded
Cut and adjust the dimensions with the panel 1 2
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11. THE TOOLING FOR FRAME ASSEMBLY IS STORED IN THE BUILDING 156
Mounting of the tooling to be done (Marzio’s team could be help)
The SCAFFOLDING is required
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12. Specific portable milling machine for chamfering have been developed
5- MACHINING
Dedicated milling machine for the U-frame components will be installed in the building 156
Specific portable milling machine for chamfering have been developed
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13. PART 2: EXTRUDED CORNER ASSEMBLY
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14. Material: Aluminium EN AW-6082 T6 Process: MIG
1- WELDING CONFIGURATIONS FOR EXTRUDED CORNER TO JOIN THE PANELS
Material: Aluminium EN AW-6082 T6
Process: MIG
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15. CERN TRIALS Results PRELIMINARY TEST: German proposal T15: T15mag x100
T15 MACRO:
- Penetration: 10.38mm (from the root to the surface)
Micro-Cracks[1001] at the root (red frame),
not permitted according to the level B of NF-EN-ISO
Few gas porosity [2011] permitted according to the level B
of NF-EN-ISO <1% melt area.
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16. Results PRELIMINARY TEST: - T14
CERN proposal:
Results PRELIMINARY TEST:
- T14
40º?
T14 MACRO:
Penetration 10.43mm (from the root to the surface)
Few porosity [2011] permitted according to the level B
of NF-EN-ISO <1% melt area
Lack of fusion at the root [4013] not permitted
according to the level B of NF-EN-ISO-10042
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17. The piece will be tested in order to validate the design:
2- TEST PIECE
The piece will be tested in order to validate the design:
3- QUALITY LEVEL & NON-DESTRUCTIVE TEST DURING PRODUCTION
The quality level and the different possibilities for NDT to perform on the welds should be checked.
4- WELDING OF THE EXTRUDED CORNER TO THE U-FRAME
The configuration for this joint will be discussed & defined
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18. COMPONENTS DELIVERED U-FRAMES CORNERS By the end of this month
First batch available
Second batch to be defined
U- FRAMES BEAMS
ADDITIONAL EXTRUDED CORNER FOR TEST PIECES
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19. THANKS FOR YOUR ATTENTION MERCI POUR VOTRE ATTENTION
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