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Update on Al-flex production

Update on Al-flex production. A. Di Mauro, WP6 meeting, 29/10/2013. Status of FHR orders. 2 x 15 m m Al coating on 25 m m APICAL foil prepared and drilled by FHR (one foil for CERN, one for Torino) -> delivered

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Update on Al-flex production

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  1. Update on Al-flex production A. Di Mauro, WP6 meeting, 29/10/2013

  2. Status of FHR orders • 2 x 15 mm Al coating on 25 mm APICAL foil prepared and drilled by FHR (one foil for CERN, one for Torino) -> delivered • 2 x 25 mm Al coating on 50 mm APICAL prepared and drilled by FHR (one foil for CERN, one for Torino) -> delivered

  3. Al-flex production test n.1 • 1st test of 15 mm Al coating on 25 mm APICAL foil provided by CERN (Rui’s workshop): failed, Al attachment too weak due to substrate not properly prepared (both by CERN and FHR) • 2nd test of 5 mm Al coating on 50 mm APICAL sample foil prepared by FHR (modified plasma cleaning prior to coating): good adhesion, process seemed ok to go ahead

  4. Al-flex production test n.2 • Chemical etching of 15 mm Al coated foil delivered in September didn’t work due to too dense Al layer: several hours bath could not remove it (usually < 1 h) , in addition too inhomogeneous (in some places it works while in others not) • Other issues: • Presence of fibres embedded in the Al • Presence of black film under the Al

  5. Black film under Al after etching (orange is kapton after scraping the black film) Possible reason: plasma cleaning done at 2x10-5 mbar, without adding Ar? Usually it is done at 10-3 mbar. To be confirmed by FHR process engineer in phone meeting on Wed 30.

  6. Fibres “embedded” inside Al, pictures taken before chemical etching

  7. Effect of fibres, pictures taken after failed chemical etching

  8. Observations on 25 mm Al coated foil • Delivered last week, more than 1 month delay probably due to issue in production • Too shiny: good adhesion but again too dense Al due to not properly prepared substrate • Presence of fibres and small Al balls • To be returned, it’s not worth even to try etching…

  9. Actions • In a phone meeting with FHR on Fri 18/10 (before the delivery of the 25 mm Al foils) we discussed the issues observed for the 15 mm Al foils etching • Points to be checked by FHR and to be discussed on Wed 30 phone meeting: • Pressure during plasma cleaning prior to sputtering • Origin of fibres • Preparation of substrate • New foils will be drilled by FHR and shipped this week to CERN to be prepared according to CERN expert (Serge Ferry) procedure (sandblasting and outgassing) • Two foils will be sent back to FHR to try one with Cr layer and one w/o Cr • Two foils will be used for Al coating tests at a French company (DEPHIS) proposed by Serge which is able to implement the same procedure used for STAR flex production on larger foils • New foils (two from FHR and two from DEPHIS) should be ready for etching around mid November, goal is first Al prototypes during week 47.

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