Inner detector upgrade / IBL Activities on cooling circuits @ LAPP

1. Inner detector upgrade / IBL Activities on cooling circuits @ LAPP LAPP team Jacky Ballansat, Patrick Baudin, Pierre-Yves David, Pierre Delebecque, Sabine Elles, Mohamed El Kacimi, Nicolas Massol, Thibaut Rambure, Jean Tassan, Theodore Todorov, TamerYildizkaya

2. 1 – IBL Cooling lines Layout pp1-pp0 INLET OUTLET Manifold connexion LAPP Fitting 1.7mm LAPP Fitting 2.2mm Ceramic PP0 brazed sleeve Beam Pipe Stave Ti ID 2.0-OD2.2 Ti ID 1.5-OD1.7 SS ID 2.0-OD3.0 SS ID 1.5-OD2.5 IST

3. Specifications 2 –Fittings • Small fitting, less than 10 mm : • To minimize budget material • To fit inside a limited volume • Maximum leak rate (He) : 10-8 mbar.l.s-1 @ 20bar • Pressure (bar): • Radiation level : up to 1000 Mrad • Working temperature : mini -40 °C  maxi +20 °C • Pipes dimensions : • Typical type I tubes : 1.5 and 2 mm ID, 0.1mm wall thickness • Pipe material : Titanium T40 3

4. Context 2 –Fittings • Current developments based on IBL context (but upgrade is the next step) • Fittings will be used @ PP1 (end of IST) • Developments for Upgrade …and other experiments 4

5. 3 –Fittings Fittings evolution summary 5

6. 3 –Fittings Fittings evolution summary (Baseline) • Material • Titanium grade 2 and 4 : hardness to low • Titanium grade 5 (TA6V) : same hardness as Stainless steel use for commercial fittings • Shape • Cone/cone : “random” results • Cone/toroid : good results but design sensitive to misalignment • Cone/sphere • Gliding surface treatment • PVD carbon tungsten : good to prevent “metal chips” (good hard wearing) • Graphite : should be as good as MOS2 but same results as “no treatment” ??? • MOS2 ( special attention to prevent treatment migration on cone and sphere) • Leak tightness surfaces • Cone raw from machining / sphere polished 6

7. Tests - prototypes 2 –Fittings • Prototypes “base line type” manufactured and tested • 16 prototypes made @ LAPP • 50 prototypes made in the industry • Tests motivations • Comparison between LAPP and industrial production (similar results) • Influence of the polishing • Comparison MOS2, graphite, PVD (tests on fittings + specific tests) • Influence of the heating on material characteristics ( conclusion= decreasing of the hardness !! -> no brazing !!! (for Titanium and stainless steel) • Prototypes on other devices • Stainless steel on cooling loop prototypes • TA6V on first IBL stave 0 • Other developments • Special tooling to prevent rotation and to apply the required torque : first prototypes 7

8. Leak tightness studies 2 –Fittings • Issue • Connection between samples and test device seemed not as good as the fitting itself • Difficulties to validate the samples if there were other leaks • No problems @ room temperature but leaks appeared @ -40 °C (He 20 bars) • Actions • He test of the vacuum seals (room temperature and cold) : seemed OK • Different type of materials for seals and flanges and shapes (and glues) have been tested • Take into account the expansion coefficients of the materials • Performed simulations • Conclusion • Leaks appear on elastomer vaccum seals @ a precise (cold) temperature. • Elastomer seal replaced by an helicoflex (aluminium + spring) • Hoped the problem would have been solved sooner • Better sample/flange connexion • New titanium seal developed • Needs “high torque level (30 N.m) 8

9. Leak tightness studies 2 –Fittings New Sample flange assembly 9

10. CO2 cooling tests 2 –Fittings • Tests of proto stave have been performed @ LAPP • Up to 50 temperature (-40 to +50 °C) and pressure cycles (5 to 60 bars) • LAPP fittings (10 mm) + swagelok mounted on the stave • 150 bars hydraulic pressure test 10

11. Next steps 2 –Fittings • New tests • Last tests to be done on 18  10mm fittings • Leak tests on new  8mm fitting (1st standard test OK (1.510-8mbar.l.s-1 @ 20bar @ -50 °C) • Developments • Tightening tool:  8mm design 11

12. 3 –EB welding • 4x10 samples welded • Good general results, no leak @ 1bar He (Techmeta) • Small amount of material inside the pipe • More metallographic analysis results from CERN in the future • Leak test :1ststandard test OK (1.810-8mbar.l.s-1 @ 20bar @ -50 °C) Metallographic analysis from Techmeta ( 1.5mm and 2 mm ID pipes)

13. 4 –Electrical break • Baseline solution : electrical break independent from the fitting • Placed on the “dismountable” side • Stainless steel pipe EB welded on a “kovar” cover • Titanium pipe EB welded on a titanium cover • Ceramic brazed on the 2 covers • Material used for brazing can contain silver • Covers have to be machined to produce prototypes Stainless steel pipe Ceramic Titanium cover kovar cover Titanium pipe • Alternative solution : electrical break included in the fitting • One part of the fitting is made of ceramic (male or female) or both • The ceramic is placed on the dismountable side • More compact than the baseline solution • First tests : no good results -> elements back to the manufacturer for polishing • Improvement: titanium coating on the contact surfaces. 13

14. CETIM audit 5 –Quality • Goals • Made by leak tightness and industrial developments experts • Survey of the design, the tests and prototypes, the methodology, the QA • Last step before production • First main recommendations • Improve the qualification of the test devices • Be more rigorous to analyse the “untypical” results • Check if a fitting machined at the limit of the tolerances fit the specifications • Perform geometrical and dimensional measurements • Better define the risks of pollution and damage • Better define the backup solutions in the case of trouble (risk analysis) • Work on the production procedure and be sure the sensible parameters are recorded • Next action • Production quality management : need a new contract and €€ 14

15. Summary •  10mm Fittings seem OK •  8mm Fittings have to be validated • EB welding : last tests to perform but we are confident • Electrical break : Base line solution to be tested – integrated solution seems more tricky • Cooling lines production : preparation in work / help of CETIM to manage the quality 15