GLAST Large Area Telescope: Tracker Subsystem WBS 4.1.4 6D: Composite Panel Fabrication Thomas Borden Stanford Linear Ac

1. Gamma-ray Large Area Space Telescope GLAST Large Area Telescope: Tracker Subsystem WBS 4.1.4 6D: Composite Panel Fabrication Thomas Borden Stanford Linear Accelerator Center Tracker Subsystem Engineer tborden@slac.stanford.edu

2. Agenda • Facilities • Tray Description and Types • Manufacturing Flow Plan • Tooling • Quality Assurance • Trays Production and EM Results • Conclusions

3. Plyform SpA, Varolo Pombia; Prime Contractor to INFN for Tray Fabrication and Assembly, Subcontractor for closeout machining Subcontractor for insert machining INFN Pisa; ESPI Test of bare panels Holographic test System can detect de-lamination defects in face sheets, between face sheet and honeycomb and between face sheets and closeouts Centrotecnica, Milan; Tray vibration testing of panels with bias circuits and tungsten Qualification levels Verification of fundamental frequency Workmanship Facilities Carbon-Fiber Wall

4. Tracker Mid Tray

5. Tray Types

6. Manufacturing Plan Production Flow Diagram Machine Closeouts (outside Vendor) Incoming Material receiving Inspection ref I.L. 02-105 Dimensional Verification of Closeouts Face Sheet Lay-up ref I.L. 02-106 Install Inserts ref I.L. 02-117 & I.L. 02-118 Assembly of Face Sheet with Honeycomb with Redux 312 UL Dimensional Verification of inserts Assembly of Face Sheet/Honeycomb and Closeouts ref I.L. 02-118 Dimensional Verification and ESPI Testing (workmanship)

7. Manufacturing Plan Production Flow Diagram Cont. Assembly of Bias Circuits to Panel Ref I.L. 02-118 Assembly of Tungsten to Panel Ref I.L. 02-118 Final Trimming and Cleaning Ref I.L. 02-116 Final Dimensional Verification, weighing and QA Workmanship Vibration Testing at Centrotechnica Ship to INFN Ref I.L. 02-119 All assembly processes per LAT-PS-01584

8. Tooling • All assembly tooling documented and released • All assembly tooling, and procedures, “proof tested” with EM hardware • Additional copies of “standard” tray tooling in production • Sufficient tools available to support production rate of 10 standard, 4 thick, one top and one bottom tray(s) a week

9. Tooling Tray assembly bottom plate Tray assembly top plate

10. Tooling Closeout bars

11. Tooling Closeout Insert Assembly Tool

12. Quality Assurance • All processes controlled by ISO approved procedures at Plyform (I.L. 02-111, I.L. 02-112, I.L. 02-113) • Regular INFN-Pisa oversight at Plyform • Data Base Developed • Nonconformance Reporting • Plyform nonconformance reporting system per I.L. 02- • LAT-PS-01584 specifies the following major Nonconformance reporting limits require halting production: • Rejection during dimensional inspection of more than 4 of the trays produced out of a continuous sample of 40 trays. • Rejection during dynamical tests of more than 4 of the trays produced out of a continuous sample of 40 trays. • Accidents resulting in irreparable physical damage (serious enough for tray rejection) to more than 2 of the trays produced out of a continuous series of 40 trays.

13. Data Base • Main form: • select tray type • access all tray data • Tray data sheet: • assembly data • bare panel measurements • final tray measurements (TBD) • subcomponents IDs and data • click on buttons to access details Luca Latronico – INFN Pisa

14. Data Base continued • Bare panel dimensions (after clicking on dimensions button): • plots measurements of reference points along tray structure • plots sides BD/AC • flatness, orthogonality, parallelism seen by moving slide bar Luca Latronico – INFN Pisa Luca Latronico – INFN Pisa`

15. Data Base continued Each submask containing detail measurements data and has a clickable legend for reference – MCM legend shown here for example Luca Latronico – INFN Pisa

16. Data Base continued Connected to Ladders DB – this mask tracks ladders IDs, location and currents (pre-encapsulation and post-encapsulation) as measured at G&A/Mipot. Location/names given according to LAT-TD-00376 convention, e.g.: F – Front Side B - Back Side 0 - connected to FE 0 side …. 3 – connected to FE 23 side Luca Latronico – INFN Pisa

17. GLAST:Gamma Ray Large Area Telescope Trays Production & E.M. Results R. Bagagli INFN - sez. Pisa

18. E.M. Tray Production

19. E.M. Results: ASSEMBLING IMPROVEMENTS • 1) Dimensional Check procedure on the tool: • measure the tool in six points with a caliber • fill a form to compare the reference values with the measured values • If measured values are otuside ±0.03mm, then the operator has to adjust the lateral wall and to check again the value

20. E.M. Results: ASSEMBLING IMPROVEMENTS Glue-line on the sandwich with dispenser on the bonding area (to avoid no-bonding area) Vacuum bag at standard temperature (to avoid air inclusion) • The glue fills all the bonding area • The exceeding quantity goes out and will be removed in Refining Step

21. Upper plate Reference wall Tray Skin Lower plate Tray assembly tools Tungsten assembly tool Tray assembly tool Tray assembly rate capability: 3 trays/day Trimming tool Kapton assembly tool

22. E.M. Results: DIMENSIONS

23. E.M. Results: FLATNESS

24. E.M. Results: ORTHOGONALITY & PARALLELISM

25. E.M. Results: TRAY DATABASE

26. Tests

27. Bare Panel: N.D.I. Test

28. Bare Panel: N.D.I. Test ESPI: Thermal Loads very effective to detect bare panel defects Skin-closeout debonding Honeycomb crash Honeycomb – Skin debonding

29. TG07: Bare Panel + W + Bias Plane ESPI: Vibration TEST 817Hz first resonance mode 1860Hz second resonance mode

30. Conclusions • All documentation in place. • Database in place. • Production Readiness Review scheduled for April 15, 2003. • All tray materials needed are delivered or on order and will be available before need date. • Tray production will begin on May 1, 2003