CLIC WORKSHOP 20133 HIGH GRADIENT DAY – 31/01/2013 TECHNICAL CAPABILITIES – MECACHROME France

1. CLIC WORKSHOP 20133 HIGH GRADIENT DAY – 31/01/2013 TECHNICAL CAPABILITIES – MECACHROME France PRESENTATION sandrine.lecureuil@fr.mecachrome.com & al

2. MECACHROME OVERVIEW 10 sites: Headquarters : Amboise 8 production sites 1 R&D center 1 engineering center Aeroengines Aerostructures Automotive Tanger Tunis Ville Saint Laurent Vibraye Mirabel Sablé-sur-Sarthe Aubigny sur Nère Amboise Toulouse

3. Production capabilities – Mecachrome / Mecahers

4. Typical parts– Mecachrome AERO ENGINES AUTOMOTIVE AERO STRUCTURES WP - Landing gear bay Iron cast blocks Large Cases and Disks (1,2-2,5 m) ) • Main customers • RENAULT • Key technologies: • Iron cast Machining • Vermiform • Burn in • Assembly • Main customers : • Rolls Royce • Snecma • ECF • Key technologies: • Combined milling/turning machine (ITV) • Ceramic milling • High-pressure turning (with double railhead ram) • Main • Customers : • Aerolia • Key Technologies : • B E • UGV machining • Spot stamping • Riveting

5. RADIO FREQUENCY QUADRUPOLE - Machining Collaboration : CEA IRFU / MECACHROME Scope: Machining, Assembly Photo CEA Saclay RFQ IPHI

6. NANO MACHINING / MECACHROME R&D Center 5-axis CNC turning milling machine Technical characteristics: X axis travel 350 mm Y axis travel 150 mm Z axis travel 300 mm B and C axis travel 360 degrees Swing capacity up to 20‘’ Air bearing Turning spindle 10,000 rpm Air bearing Milling spindle 60,000 rpm Precision 34 picometers resolution rules (0.034 nanometers) Incremental programming 0.01 nanometer Axial and radial spindle error ≤ 25 nanometers B axis axial and radial error ≤ 100 nanometers Shape defect ≤ 0.15 μm on diameter 75 mm Surface finish Ra ≤ 3.0 nanometers

7. NANO MACHINING / MECACHROME R&D Center Our structures have been tested at CERN on 22 February 2012. Beyond the dimensional control, these are measures which demonstrates our expertise in achieving accelerating cavities.

8. NANO MACHINING / MECACHROME R&D Center Aluminum mirror for satellite application on its support delivery Results : PV = 0.335 µm Ra = 0.001 µm RmS = 1,92 nm Copper disk - accelerating structure Results : PV = 0.807 µm Ra = 0.002 µm RmS = 1,72 nm

9. SEM inspection capabilities / MECACHROME R&D Center Working on cuttingparameters to avoid grain pullout

10. Innovative Manufacturing - Additive manufacturing process ALM = Parts are manufactured using CAD data by the addition of material, layer by layer • The powder bed is melted in a vacuum chamber • No moving parts, electron beam scanning faster than a laser beam • The high energy beam melts the powder producing 100 % dense parts in controlled thermal conditions • Homogeneous focusing on the entire Build surface • Build reports are generated for each batch with monitored data during the entire cycle

11. Innovative Manufacturing - Additive manufacturing process • Advantages and limitations of the process: • Achieves close to the raw scores (as a foundry), but with similar characteristics on a forged (excellent health matters). • No residual stresses and distortions. • Material: Titanium Alloy TA6V (sheet material available). • 2 build configurations (size max.): 200 x 200 x H 332 mm or Ø 300 mm H x 210 mm. • Geometric Tolerance: + / - 0.2 mm • Minimum thickness : 1.2 mm • Important roughness Ra ~ 12 microns (possibility of improvement post processing). • Freedom of design (concept parts embedded, network structure of ...) not achievable by any other process … • Benefits achievable by design optimization (design around functionality -> gain of material). • Short production cycle, production time is independent of the complexity of the parts. • Machining is limited to functional areas, drilling … leading to a much reduce material removal rate • Much lower environmental impact than the traditional method, only the material needed is consumed

12. Advanced Materials : Powder Metallurgy – Metal Matrix composite Metal powder (Matrix) Reinforcementt Matrix Reinforcement From powder to advanced material From lab scale to industrialization Know-how : ball milling, Spark Plasma Sintering ( on-site installations) Hot Isostatic Pressing, Hot extrusion (sending subcontracting) Examples of development: Steel-TiC, Ti-TiC, Al-SiC, ODS-steel, … Ball Milling Can or die filling Composite powder HIP Extrusion SPS Thermal treatment, machining…. Dense material Part

13. Advanced Materials - Spark Plasma Sintering : on-site installation Under pressure and pulse energized, the temperature can instantly rise to 2000℃ above the ambient temperature, resulting in the production of a high quality sintered compact in only a few minutes. Our machine is the worldlargest unit the diameter can reach 350 mm Processes: consolidation of powder (reactive or not), assembly / coating (solid / solid, solid, powder, solid)Materials: Metals, ceramics, composites (metallic and polymeric), FGM (density, composition) Main advantage: Short cycle time - Conservation of fine microstructures (nanomaterials, metal matrix composites ...)- Ability to consolidate "difficult" materials (tungsten carbide, ceramics transparent ...)- simple, reliable and process to industrial scale Assembly of steel matrix composite with steel SPS microstructure is finer than HIP (Hot Isostatic Pressing) microstructure

14. PEM ELECTROMACHINING / MECACHROME Aubigny The PEM process is an electrochemical cavity-sinking erosion process with vibrating electrodes Technology on progress – unit operationnal in March 2013

15. Coating / MECACHROME Vibraye PECVD : Plasma Enhanced Chemical Vapor Deposition Process for chemical vapor deposition assisted by plasma, used to deposit thin films on a substrate from a gaseous state (steam). Chemical reactions take place in the process after creating a plasma from the gas reactor. The plasma is generally created from this gas by radio frequency or by an electrical discharge between two electrodes. An adherent film, hard and thinHigh hardness (approaching that of diamond (> 2500 Hv)Relatively low deposition temperatures (<300 ° C)An extremely low coefficient of frictionHigh resistance to wear, shock and scratchesLimitations : plasma interaction with the substrate can lead to inhomogeneity's deposits parts of complex geometry. DLC Substrat

16. Thank you very much for your attention sandrine.lecureuil@fr.mecachrome.com Loic.guillonneau@fr.mecachrome.com marc.noyer@fr.mecachrome.com www.mecachrome.com