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Cooling Connections Status Report: LBNL Effort

Cooling Connections Status Report: LBNL Effort. December, 2001 N. Hartman, E. Anderssen, M. Gilchriese, F. Goozen, T. Johnson, T. Weber, J. Wirth. Current Status. Luer Lock leak tests Initial Al/AL fittings fully Qualified Luer lock demating tests

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Cooling Connections Status Report: LBNL Effort

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  1. Cooling Connections Status Report:LBNL Effort December, 2001 N. Hartman, E. Anderssen, M. Gilchriese, F. Goozen, T. Johnson, T. Weber, J. Wirth N. Hartman LBNL

  2. Current Status • Luer Lock leak tests • Initial Al/AL fittings fully Qualified • Luer lock demating tests • Al/Al luer locks have not shown binding under even very conservative test conditions • Laser Welding • Material problems solved (for 3003 and 1060) • Have successfully welded sector tube with variseal fittings • Must do more tests for higher confidence • Other tubing sizes • 4 mm, 8 mm, and Capillary tubing have all been obtained in aluminum for testing • Fitting Comparisons • Lower Mass fittings have been designed and await fabrication • Both Luer lock and indium, for sector size, in al N. Hartman LBNL

  3. Al PEEK Fitting Test Specimens – Baseline Luer Lock Luer Lock Pieces (PEEK and Aluminum). Assembled Fitting. N. Hartman LBNL

  4. Luer Lock Results N. Hartman LBNL

  5. Joining Methods – Laser Welding N. Hartman LBNL

  6. Laser Welding Problems • Tube Material – Batch 1 • Reported as 3003 AL • Laser Welding very Successful • Later found to be 1060 AL (almost commercially pure) • Tube Material – Batch 2 • Ordered 3003 AL – different vendor • Tested as 3003 AL • Would not laser weld (microcracks on cooldown) • Tube Material – Batch 3 • Ordered 3003 AL • Material is 1060 Al • Vendor’s source is unreliable, and this will not change N. Hartman LBNL

  7. Laser Weld Solution • Configure joint to favor tube material • Tube material (whether 3003 or 1060) typically has less alloying elements than 6061 • Joint configuration (raising tube) alloys tube to be preferentially melted, increasing its concentration in melt zone • This creates a less alloyed weld region, which is less brittle • Successfully demonstrated Weld Zone Tube melts Into chamfer Weld Zone Old Approach New Approach N. Hartman LBNL

  8. Fitting Comparisons - Mass Fitting Volume Smeared over hoop at radius 210 mm, 50 mm long • Reduced Mass Luer and Sector Size Indium Fittings • Designs completed but not yet fabricated • Fittings designed with features for laser welding • Expect delivery of parts in mid-january • Laser welding and testing to be done in february N. Hartman LBNL

  9. Fitting X-section Comparisons Current Luer Design New Luer Design Sector Indium Design Old Variseal Design N. Hartman LBNL

  10. Upcoming Work • Reduced mass luer and indium fittings • Testing to be done in february (as mentioned earlier) • Capillary testing • Robustness tests • Bend/unbend repetitions • Pressure/leak testing (with swage lock connectors) • Laser Welding tests • Made in low mass luer or indium fittings • Full system prototype • Complete cooling circuit prototype from pp1 to sector • All “real” fittings – all laser welded (including 4/8 mm tubes) • Completed sometime before next summer • Plans to test in marseille with evaporative cooling plant N. Hartman LBNL

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