FPIX Upgrade – Status of CO 2 Cooling S tudies

1. FPIX Upgrade – Status of CO2 Cooling Studies S.Grünendahl, FNAL for the FPIX Upgrade Mechanical Group H. Cheung, G. Derylo, S.G., S. Kwan, C.M. Lei, E. Voirin (Fermilab) K. Arndt, Q. Liu (Purdue) S.Grünendahl – CMS Pixel CO2 Meeting

2. FPIX CO2 Cooling Areas of Progress • Tests since previous meeting:: • 2/12 1.4mm ID outer half-disk loop • 2/14 1.4mm ID inner half-disk loop • 2/21 1.6mm ID full length loop • 2/27 Multi-blade disk w/TC 5022 pocket slots for blade-ring joint • FEA study of through slot joint Port Cards and POH Pipes and Cables 3 Half Disks End Flange CO2 cooling tubes and flex cables DC-DC converters S.Grünendahl – CMS Pixel CO2 Meeting

3. Loop Tests Update Existing Optional Supply & Return DC-DC & POH FPix Detector Copper Lines Concentric Manifolds Evaporator Evaporator Tube Heat Exchanger • Full length stainless steel tubing assemblies with dummy heat loads • Measure temperatures vs. flow & pressure drop • Initial finding: pressure drop larger than in simulation • Adding concentric heat exchanger, to guarantee subcooled liquid, and fine-grained RTD placement to confirm transition to two-phase flow • New studies: • variations in tube diameter • inner/outer half lengths configurations 1st Half-Disk Supply Line Return Line 2nd Half-Disk 3rd Half-Disk Supply Line Return Line Near SCEndflange Inside FPix SC Manifold  PP1 PP1  PP0 Inside FPix S.Grünendahl – CMS Pixel CO2 Meeting

4. Loop Setup subcooler Fine grained RTD placement to locate onset of two-phase flow S.Grünendahl – CMS Pixel CO2 Meeting

5. 1.6mm ID Full Loop Test S.Grünendahl – CMS Pixel CO2 Meeting

6. Loop Tests: Combined Results S.Grünendahl – CMS Pixel CO2 Meeting

7. Loop Tests: Combined Results II S.Grünendahl – CMS Pixel CO2 Meeting

8. Joao’s Calculations • Outer loop, full heat load, lowest stable experimental mass flow (0.65 g/s) and 1.5 times l.s.e.m.f. (1.07 g/s) S.Grünendahl – CMS Pixel CO2 Meeting

9. Joao’s Calculation I S.Grünendahl – CMS Pixel CO2 Meeting

10. Joao’s Calculation II S.Grünendahl – CMS Pixel CO2 Meeting

11. Calculation vs. Experiment • Lots of discussion and progress on understanding of difference simulation vs. experiment • Many calculations by Joao (Thanks!) • My conclusion: • all except Delta P seem to agree • difference maybe not all that surprising:Even (easier) single phase flow depends a lot on parameters like e.g. tube roughness that are hard to control (From Eric & Joao) S.Grünendahl – CMS Pixel CO2 Meeting

12. Loop Test Conclusion • Both parallel (with 1.4mm ID) and serial (with 1.6mm ID) are viable • Decision will have to take into account complexity, material accounting and redundancy/failure tolerance considerations S.Grünendahl – CMS Pixel CO2 Meeting

13. Multi-blade Tests: TC 5022 in Pocket Joints • Improved joint geometry control (dry fit to equalize radial play for all blades before assembly) ∆T from CO2 to silicon center = 6.9 6.7 6.4 7.6 -16.3 ∆T=2.5 -13.8 -16.4 ∆T=1.7 ∆T=0.6 -13.2 -14.7 ∆T=1.0 -15.9 ∆T=1.0 -13.7 -14.9 ∆T=1.0 -13.9 -16.4 ∆T=2.0 -12.0 -14.4 -11.7 -13.4 ∆T=1.1 -12.8 ∆T=-0.3 -12.9 -13.3 ∆T=0.6 -12.6 ∆T=0.3 -12.5 -12.4 ∆T=0.1 -13.1 ∆T=0.2 -13.3 -13.2 ∆T=1.9 -15.2 ∆T=0.3 -13.5 -13.4 ∆T=2.1 -15.6 ∆T=0.3 -13.7 -13.1 ∆T=0.2 ∆T=1.5 -15.2 -13.3 ∆T=2.4 -15.7 ∆T from CO2 to outer ring = 2.9 3.4 2.9 3.0 ∆T from CO2 to inner ring = 3.5 4.1 3.6 4.0 S.Grünendahl – CMS Pixel CO2 Meeting

14. Ansys vs. Experiment Good match using data sheet material properties and nominal dimensions (i.e. no fudge factors) S.Grünendahl – CMS Pixel CO2 Meeting

15. Conclusion • TC 5022 pocket joint fully qualified • Necessary joint QC depends on blade manufacturing tolerances; in any case doable, even if a bit labor intensive S.Grünendahl – CMS Pixel CO2 Meeting

16. Blade-Ring Joint FEA Studies • Motivation: Through slot might have practical advantages for half-disk assembly Nominal joint parameters (material & thicknesses) Conclusion: radial heat transfer less important => might want to look at through slot again (Caveat: Studies without CF in joint area – repeat with CF) S.Grünendahl – CMS Pixel CO2 Meeting

17. Blade-Ring Joint FEA Studies II • Better structural strength if carbon fiber cladding continues into joint pocket/slot • Simulation looks ok S.Grünendahl – CMS Pixel CO2 Meeting

18. FPIX Cooling Layout ‘Decision Tree’ (from Kirk) Left vs. Right HCs Symmetric (3 main lines) or Asymmetric (2+2 main lines) HD Inner + Outer in Parallel (1.4mm or 1.6mm ID HD tubing) HD Inner + Outer in Series (1.6mm ID HD tubing) 3 + 3 2 + 4 3 inners + 3 outers Outer-inner-outer + Inner-outer-inner S.Grünendahl – CMS Pixel CO2 Meeting

19. Full geometry Z loc. TBD shown 491mm from IP 396 291 η = 1.3 η = 1.6 η = 2.1 161 η = 2.5 45 2x8s 2x8s 2x8s 2x8s 2x8s 2x8s

20. Segmentation alternative #0 - Baseline - 1st HD on one main line + 2nd and 3rd HDs in parallel on the other main line = two main cooling loops per Half-Cylinder 4 hits η = 1.6 3 hits η = 2.1 2 hits η = 2.5 1st disks 2x8s 2x8s 2x8s 2x8s 3 hits 3.5 hits η = 1.6 3 hits η = 2.1 η = 2.5 2nd + 3rd disks 2x8s 2x8s

21. Segmentation alternative #1 – two cooling loops per Half Cylinder (Total 4 cooling loops per end) 4 hits η = 1.3 η = 1.6 3 hits η = 2.1 2.5 hits η = 2.5 Outer-inner-outer 2x8s η = 1.3 η = 1.6 2x8s 2x8s 3 hits η = 2.1 3.5 hits 2.5 hits η = 2.5 Inner-outer-inner 2x8s 2x8s 2x8s

22. Segmentation alternative #2 - All outers in parallel + all inners in parallel on two main cooling loops per Half Cylinder 4 hits η = 1.6 3.8 hits η = 2.1 1.5 hits η = 2.5 All Outers 2x8s 2x8s 2x8s 3 hits 2.5 hits η = 1.6 3.5 hits η = 2.1 All Inners η = 2.5 2x8s 2x8s 2x8s

23. Segmentation alternative #3 – three cooling loops per two Half-Cylinders (Total 3 cooling loops per end) 3 hits η = 1.6 3.5 hits η = 2.1 3 hits η = 2.5 2nd + 3rd disks 2x8s 2x8s 2x8s 2x8s 4 hits η = 1.6 3.5 hits η = 2.1 3 hits η = 2.5 1st + 3rd disks 2x8s 2x8s 2x8s 2x8s

24. Segmentation alternative #3 – three cooling loops per two Half-Cylinders (cont.) (Total 3 cooling loops per end) η = 1.6 4 hits η = 2.1 4 hits 3 hits η = 2.5 1st + 2nd disks 2x8s 2x8s 2x8s 2x8s

25. Summary • Loop tests show both parallel cooling loops with 1.4mm ID and serial loops with 1.6mm ID are viable solutions • Multi-blade tests: TC 5022 in pocket slot has been fully qualified for blade – ring joint • Further multi-blade assembly tests for carbonized and soldered joint are in preparation • Discussion on optimizing the FPIX cooling loop connection scheme is underway S.Grünendahl – CMS Pixel CO2 Meeting

26. Backup Slides • Progress in related areas, from Purdue • Delta p vs. flow for different diameters • Tables for loop measurements S.Grünendahl – CMS Pixel CO2 Meeting

27. Progress@Purdue (from Kirk): Custom tools for pick-and-placing the HDI onto the 2x8 bump-bonded module • Designed custom front-end tools to pick-and-place HDI onto bare 2x8 bump-bonded modules. • Semi-automated module assembly trials with prototype HDI will take place once these custom tools are fabricated. • Work in progress to build a practical design and installation sequence for mounting, connecting, and cooling double-stacked port cards/POH in service (half) cylinders.

28. Delta P vs. Flow S.Grünendahl – CMS Pixel CO2 Meeting

29. Loop Measurement Tables S.Grünendahl – CMS Pixel CO2 Meeting