Hybrid assembly, bonding and testing

1. Hybrid assembly, bonding and testing Gabriella Pásztor UC Riverside Tracker week, Module Production meeting 23 October 2003, CERN

2. Reception Procedure well defined, some work still needed on DB issues • Unpacking • Registration in DB (via Big Browser at present) • Upload FHIT data measured at Hybrid SA to DB(due to problems with the CDs burned at Hybrid SA not done properly for previous batches; from next shipment data on memory stick) • Put hybrids into our own storage boxes • Visual inspection • Mark faulty hybrids in DB (special action panel at present, separate table in future) • FHIT test • Upload FHIT data to DB • Send Cat. B, C and ~20% Cat. A hybrids to Strasbourg for QA (include APV tracking data, summary of inspection results) • Storage until assembly G. Pasztor: Hybrid assembly, bonding and testing

3. Assembly Tooling - Assembly plates: • TOB (PA + spacer) - 60 PAs / plate • Different alignment tools for r- and stereo PA placement • 2 TOB - 16 hybrids / plate(+1 prototype plate for r-) • 2 TEC with short PA (rings 1,3,4,7) - 20 hybrids / plate(+1 prototype plate for r-) • 2 TEC with long PA (rings 2,5,6) - 12 hybrids / plate • 2 TIB/TID with short PA (all TIB and TID ring 3) - 24 hybrids / plate(+1 prototype plate for r-) • 2 TID with long PA (rings 1, 2) - 16 hybrids / plate • (+1 universal plate - 12 hybrids/plate) To be completed: • Curing box and storage for unused assembly plates • Installation of second vacuum pump • Spare for PA pickup tool G. Pasztor: Hybrid assembly, bonding and testing

4. Assembly All hybrid types (except TID) assembled (not all with final tooling): • 523 hybrids in total (142 TEC, 160 TIB, 221 TOB) Known problems: • Systematic misplacement of PA up to ~70 m in gantry Y in extreme positions, not critical for APV - PA bonding but to be corrected • Flatness of the assembly (small fraction of hybrids affected, all believed to be acceptable for module assembly) • Glue thickness, contact between the glued surfaces (visually inspected after assembly, if necessary hand-repaired) • Spacer placement especially for TEC hybrids (hard to find in visual inspection, obvious during bonding) Planned improvements: • Automatic upload of xml with type change record after assembly (still not possible in current - new - version of Big Browser) • Further recovery and safety features Aerotech: new sw version with fix for MMI error (2D calibration) today! G. Pasztor: Hybrid assembly, bonding and testing

5. Bonding • 32 bonding jigs for TIB/TID/TEC/TOB ready - sufficient for one day’s work • All hybrid types (except TID) have been bonded, all programs ready for final PA masks • Bonding time per hybrid: 6-10 min depending on #APVs • Different bond parameter settings for RMT and Planar PAs • Sensitive to planarity of APVs and PAs • Bond pull tests still done on all hybrids due to observed variations in bonding quality • Pull tester PC interface ready allowing quick, automatic entry of pull test data into bonding DB • RMT PAs show large bond quality variations slowing down but not stopping the production • Serious whisker problem for Planar PAs (next page) G. Pasztor: Hybrid assembly, bonding and testing

6. Bonding • Whiskers - threads of aluminum created during the bonding process from displaced substrate metal - can cause shorts to adjacent channels in the 2nd row of the PA bonds (APV side) • More than 50% of Planar PAs effected • Worst case so far: 3 shorted pairs of channels but visual inspection showed ~40 potential shorts requiring 30 minutes of repair • Several modifications tried but no solution yet: • Modification of bonding parameters • Change from 25 to 17 m wire - smaller whiskers but difficult to put down the bond, tool skids on the bondpad • Oxidation by heating to 400 C in air for >45 minutes - works well but not practical (equivalent of 10 years normal aging) • Possible solution: changing the acceleration parameter - not permitted by Delvotec to date • No whisker problem reported by the US where all TOB ~ 35% (and possibly TEC Planar ~ 20%) PAs will be bonded on K&S machines G. Pasztor: Hybrid assembly, bonding and testing

7. Testing Tooling: • Five types of hybrid fixture plates: • 2x4 TOB/TEC r- • 4 TOB/TEC stereo • 4 TIB r- • 4 TIB stereo left • 4 TIB stereo right To be done: • Small modification on stereo plates • Intermediate plate for TIBs (only a single plate available) • 2nd set (allows the preparation of the next test while the current one runs) • 2nd cooling box operational, 1st under repair • 2nd test station to be completed (all parts are available except flow meter and pulser electronics) G. Pasztor: Hybrid assembly, bonding and testing

8. Testing Thermal cycle test result summary based on 316 (v15) hybrids: • 2 faulty (broken cable, non-working calibration pulse) • 30 with small problems (opens, shorts, noisy channels) - OK • >11 with PLL problem in cold - OK • ~15-20 fake faults due to problems in our sw & hw (mostly understood) • Excessive noise (APV edges, comb-like structure) • Initialization problem • Error in open detection due to staggered bonds on TIBs • Lower pedestal for a TEC batch SW improvements under development: • Automatic detection of PLL failure in cold and check whether ‘manual’ restart procedure works on the failing hybrid • Investigate the possibility of • pipeline scan (but better to catch faulty hybrids before PA mounting!) • DCU temperature calibration • Revisit the HYBRIDMEASUREMENTS DB tables:separation of compulsory tests from QA tests on a sample basis G. Pasztor: Hybrid assembly, bonding and testing

9. Packaging • Ship typically 50 hybrids together • Typically four hybrid boxes sealed in low humidity condition into transparent ESD bags and then surrounded with bubble foil to protect against mechanical damage • Empty space in cardboard box filled with foam bubbles, for further protection the package is put into a second cardboard box • Some reports on hybrid damage from the TEC communitymost probably due to the quality of large hybrid box: flexible wall,problem with kapton tapes due to black dust coming from box G. Pasztor: Hybrid assembly, bonding and testing

10. Hybrid storage box • Present system (hybrids taped into black ESD boxes of two sizes) inadequate: black dust from box weakens the stickiness of tape, larger box mechanically not robust, taping dangerous • Most promising options for final box: • Preferably transparent ESD boxes in two sizes (25% requires large size) • (OR custom made black boxes in one size) • To hold the hybrid in place use clean foam inserts • (OR molded black ESD insert) • Boxes should be reused, otherwise too expensive1000 small boxes orderedfurther order only after decision on box type larger box ~twice the price • REQUEST TO PRODUCTION CENTERS: please send back our boxes a.s.a.p.we are short of boxes for next batch G. Pasztor: Hybrid assembly, bonding and testing

11. Production status and plan • Production stopped on Sept 10 due to kapton cable problem, since then only a few hybrids have been assembled on special request • >150 hybrid connectors inspected, >100 retrofitted with stiffenerNote of warning: recently we found several FHIT connection failures of TIB hybrids just after retrofitting. Statistics: • 4 failures of 75 TECs • 0 failure of ~10 assorted hybrids • 1 failure of 19 TOBs (cracked lines soldered, failure due to soldering) • 4 failures of 8 TIBs (from the failing hybrids only 1 had cracks observed in previous visual inspection) - under investigation! • Hybrid production restarted on Oct 17first 50-100 TIB hybrids may arrive to CERN ~Nov 3 (earliest) followed by more TIBs, TOBs and finally TECs • Earliest shipment of new assembled hybrids mid-Nov to Italy, Nov/Dec to US and just before the holidays to TEC community G. Pasztor: Hybrid assembly, bonding and testing

12. Production http://cern.ch/gpasztor/cms/hybridassembly/hybrid_counts.xls G. Pasztor: Hybrid assembly, bonding and testing

13. Throughput Reception (unpacking, visual inspection): Expected peak: 54 / day Max. until now: 214 in 3 days Achievable rate: 20 / hour (estimated for thorough inspection) FHIT test: Expected peak: 54 / day Max. until now: 141 on one day Achievable rate: 40 / hour (achieved) Assembly: Expected peak: 54 / day Max. until now: 36 on one day Achievable rate: 8 / hour (achieved) G. Pasztor: Hybrid assembly, bonding and testing

14. Throughput Bonding: Expected peak: 24 / day if all Planar PAs bonded in the US Max. until now: 20 on one day Achievable rate: 32-40 / day (estimated allowing for variation in bonding quality, assuming a bonder AND a support technician) Readout test: Expected peak: 24/day Max. until now: 23 on one day Achievable rate: 12/hour (estimated if no thermal cycle during the day, thermal cycle of 4 hybrids overnight) G. Pasztor: Hybrid assembly, bonding and testing

15. Manpower requirements Technicians: Reception (visual inspection + FHIT) : 5 h / day Assembly (including preparation, inspection): 7 h / day Testing: 2 h / day Bonding: 12 h / day (8h bonder, 4h support) Packaging (including final visual inspection): 2 h / day 28 h / day Physicists (NOT including repair and maintenance of HW and SW): Reception, packaging: 0.5 day / week Assembly: 1 day / week Bonding: 1 day / week Testing: 1 day / week 3.5 days / week If higher throughput required (not a distant possibility), manpower must be scaled up! Tooling, equipment should be available. G. Pasztor: Hybrid assembly, bonding and testing