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HiRadMat Window Design report v4.0

HiRadMat Window Design report v4.0. Specifications. Interface between machine vacuum and Atmospheric pressure 10 -8 mbar / P atm Protective atmosphere !!! Aperture min 60 mm Resist to a proton beam size on the window : 1 s = 0.5 mm. “Beam Size at the TT66 Vacuum Window”,

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HiRadMat Window Design report v4.0

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  1. HiRadMat WindowDesign report v4.0 Michael MONTEIL - 29 April 2010

  2. Specifications • Interface between machine vacuum and Atmospheric pressure 10-8 mbar / Patm • Protective atmosphere !!! • Aperture min 60 mm • Resist to a proton beam size on the window : 1s = 0.5 mm “Beam Size at the TT66 Vacuum Window”, C. Hessler, 26.02.2010 Michael MONTEIL - 29 April 2010

  3. Headlines • Be • PF-60 • Uranium • Maximal temperature in Be ; double-checking • Value • Criterion • Conclusions about Window Integrity • Specifications • Final design • Presentation • Why is the Be foil not flatter on C-C in CNGS window design ? • Thermal shockwave effects • Price • Future tasks Michael MONTEIL - 29 April 2010

  4. Different grades of Be • Luca Bruno said : IF there is Uranium, it is anyway in very low proportion. It should not be a problem for our study. Data: Brush Wellman Michael MONTEIL - 29 April 2010

  5. Be grade : PF-60 • Low rate of Beryllium oxide compare to PS-200 • So higher purity • Good quality-price ratio (Next slides…) • 1.5 to 2 time cheaper than IF-1 • Almost the same temperature distribution as pure Be and IF-1 (IF-1 a bit better…) Data V3.0 • Used in CNGS… Collaboration: J. Blanco Michael MONTEIL - 29 April 2010

  6. HiRadMat Be window PF-60 • Beam parameters at the window location • 0.5mm sigma • 450GeV • 288 bunches * 1.7E11 p+ • 1/18 Hz. • Temperature values * From A. Ferrari (EUROTeV-Report-2008-009)

  7. CNGS Be window PF-60 • Beam parameters at the window location • 0.53mm sigma at focal spot(not at window) -> difference from HiRadMat • 400GeV • 4.8E13 p+ • 1/6 Hz. • Temperature values (errors are in the order of 3% for FLUKA) * From A. Ferrari (EUROTeV-Report-2008-009)

  8. Conclusions • The Hottest spot using the FLUKA output approach gives a very conservative value, as it only occurs in a small region compare to the beam size. • The analytical approach (formula): • Using dE/dx(stopping power), it gives a conservative upper limit. It doesn’t consider that a fraction of the stopping power escapes from the window. • The restrictive dE/dx is more realistic, as it consider that a fraction of the stopping power is not deposited in the window.

  9. Maximum temperature • Maximum Value : 500°C • Criterion • According to BW : “ Regarding the exposure of beryllium material to 500°C, please be advised that the material should survive that temperature for short periods of time ” • According to L. Bruno, if the load is carried by the C-C, the maximal temperature is: Tmax(K) = Trecrystallization(K) = 0.5*Tmelting Point(K) Tmax(K) = Trecrystallization(K) = 0.5*1546K = 773K = 500°C • Conclusions : OK • Maybe beam test ? Michael MONTEIL - 29 April 2010

  10. Design • Specifications • Be & C-C • Aperture min. 60mm • DN63 conical plug-in flange • 15 cm depth maximum • Need to flatter Be on C-C (because of 500°C) • Remark • Cannot machine Be at CERN Michael MONTEIL - 29 April 2010

  11. Design • HiRadMat – Option 1 • Choices • Standard flanges only (cheaper) • Be window is assembled in lab (safety) • Conical flange (faster assembly once in experimental area) • Need to machine tube depending of carbon final thickness • Design • Conical Flange (plug-in flange) • Tube (connection conical flange <--> conflat flange) • 2 x Conflat (Window in-between) Design: J. Kortesmaa & M. Monteil (TE/VSC) Michael MONTEIL - 29 April 2010

  12. CF Flange with Be foil Data: Brush Wellman Michael MONTEIL - 29 April 2010

  13. Why is the Be foil not flatter on C-C in CNGS window design ? CNGS According to J.M. Jimenez :Main idea behind window design was to avoid “touching” the sflange from BW. JMJ agrees that HiRadMat design is better and he just noticed that we might need to machine the inner diameter of the gasket Nota: Those drawing are drafts. Above dimensions are not representative of the reality Michael MONTEIL - 29 April 2010

  14. Few important (& positive) remarks • Tightness of foil : Warranty by BW • Tightness between CF standard flanges : Experimented standard assembly Michael MONTEIL - 29 April 2010

  15. Thermal shockwave effects • Window flatter on C-C High stiffness and also no axial displacement  So no more axial vibration mode • Calculation (If window not flattered, so conservative) If c*t0 > r0 and r0 << R then SigmaMax < 2*r0/(c*t0)*E*Alpha*T0 Results : Sigma < 21 MPa Where r0 : heated region (spot) (0.5e-3m) t0 : heating period (7.2e-6 s) C : celerity (15e3 m/s) R : radius of window (0.035 m) E : 303 Gpa Alpha : 15e-6 m/m-°C T0 : Sudden temperature rise (500°C) Michael MONTEIL - 29 April 2010

  16. CF Flange with Be foil • Number of flange to order : 2 • Spare : 1 • Window installed : 1 • Price • 1944 $ * 2 = 3888 $ Data: Brush Wellman Michael MONTEIL - 29 April 2010

  17. To do : • Order Beryllium • Delivery: 4 Weeks ARO for flanges (Option 1) • Cut C-C disks • Measure thickness • Machining tube (According to calculation, deflection of Be foil is about 0.5mm) • Assembly • Test • Check that Be foil is flatter on C-C Michael MONTEIL - 29 April 2010

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  19. V3.0 slides Michael MONTEIL - 29 April 2010

  20. Solutions - Sum-up • #1: C-C (Differential pumping) • Protective atm (Nitrogen ?) • Radiations? • #2: C-C + Graphite foil (useless now) • #3: Tight steel “ring” with a C-C plate • #4: Beryllium • Safety problem • #5: C-C + Beryllium  Today Michael MONTEIL - 29 April 2010

  21. “TED @ TI2, TT40” – Beryllium version “TED @ TI2, TT40” HiRadMat – Option 2 Michael MONTEIL - 29 April 2010

  22. “TED @ TI2, TT40” – Beryllium version • Quote from BW Michael MONTEIL - 29 April 2010

  23. 2 design proposals Option 1 Option 2 Not that much Precautions for the assembly Non Standard conflat assembly (Tightness) Might be careful to not cut (shear cut) the Be foil during assembly • Life warranty on Be + flange assembly • Easy to assembly • Standard conflat assembly • Tightness OK • Not that much Nota: Those drawing are drafts. Above dimensions are not representative of the reality Michael MONTEIL - 29 April 2010

  24. 2 design proposalsCost estimationBe Foil Option 1 Option 2 Number of foil to order : 3 Spare : 1 Window installed : 1 “In case we break a foil while assembling” : 1 • Number of flange to order : 2 • Spare : 1 • Window installed : 1 Nota: Those drawing are drafts. Above dimensions are not representative of the reality Michael MONTEIL - 29 April 2010

  25. 2 design proposalsCost estimationBe Foil Option 1Flange Option 2Foil Nota: Those drawing are drafts. Above dimensions are not representative of the reality Michael MONTEIL - 29 April 2010

  26. About thickness, how does BW design their own Be foils? With (Thickness 0.25mm, radius 35mm, pressure 1.01 kPa, E 303Gpa, Poisson 0.08) Results • sedge= 305MPa > 275 Mpa !! • scenter= 297Mpa > 275 Mpa !! Data: Brush Wellman Michael MONTEIL - 29 April 2010

  27. However… • BW : “With confirm that your calculations with reference to the DB450277 assembly are correct and show over the recommended values, however, the assembly was designed using empirical data as well taking into consideration the calculated values. We have performed tests on this design and found it to be reliable, with units sold to customers over the years performing well under real-life conditions.” • Explanation • Because of plasticity effects, Be foil withstands 1 Atm (according to BW tests) even if Roark’s calculation says that it doesn’t withstand Data: Brush Wellman Michael MONTEIL - 29 April 2010

  28. To know • Be have ultra high resistance to fatigue cracking • High endurance strength level Data: Brush Wellman Michael MONTEIL - 29 April 2010

  29. Solutions #5stresses and deflection - C-C+Be under DP = 1 atm • Linear circular fixed support • 2 planes of symmetry • Geometry • Diameter f 80 mm • Thickness: 0.254 mm • Aperture: f 60 mm • Pressure 1 atm Michael MONTEIL - 29 April 2010

  30. ANSYS Study - Solutions #5stresses and deflection - C-C+Be under DP = 1 atm • Beryllium foil study • Smooth and continuous temperature distribution • Through-thickness energy deposition • Coefficient of Thermal Expansion varying with temperature • Be (pure elasticity): • Poisson’s ratio = 0.08 • High Re = 303 Mpa Michael MONTEIL - 29 April 2010

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  42. Conclusion: influence of gap reducing • So if we flatter the foil on the C-C, we reduce the Max stress (as shows ANSYS calculation with non plasticity model), maybe also stay in elastic domain (Bellow 275Mpa at room Temp).  We will manage to reduce this gap (flattering the Be foil as much as possible on C-C plate) Michael MONTEIL - 29 April 2010

  43. Easiness to reduce Gap C-C / Be Option 1 Option 2 - + Michael MONTEIL - 29 April 2010

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