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Status Report Sectors, Rings, Frame

This report provides an update on the progress of laser welding and pressure testing of sector tubes, including the completion of welding with a high yield, tests of different tube materials, and the need for further testing to ensure sector integrity under pressure. The report also includes updates on other project components such as disk fabrication and laser welding trials of capillaries.

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Status Report Sectors, Rings, Frame

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  1. Status ReportSectors, Rings, Frame December 2002

  2. Sectors Since the Last Pixel Week • Laser welding of about 40 sector tubes(Al 1060) to fittings was completed with about 90% yield for two good fittings on tube. • One sector fabricated for initial system tests. • But recognition that fault pressure in evaporative cooling system may be about 16 bar(abs), much greater than we had assumed before. • Extensive testing of baseline sector tubes(aluminum 1060) and work hardening of same • “Destructive” testing of sector made with 1060 tube to 16 bar(abs) • Extensive testing of stronger tubes(aluminum 3003) and work hardening of same. • Fabrication of 3003 samples to test laser welding to existing coolant fittings. Laser welding of 6 out of 6 samples completed successfully yesterday.

  3. Aluminum1060 Tubes

  4. Tube Deflection Tests • Measure tube deflections under pressure, with and without work hardening. Also some testing of bent sector tubes. Work hardening by External/internal pressure Measure deflection Under pressure

  5. Test Sector to 16 bar(abs)

  6. Summary of Deflections 1060 tubes only Sector edge with 1060 tube Worst spot on a sector 3003 tubes only

  7. Sector(1060 tube) after 16 bar • No catastrophic failure. Tube on edges expands inelastically. Most of region not affected. Sector construction prevents tube from expanding except on edges. GAP

  8. Other Pressure Tests • We have tested about 10 samples of the fittings welded to the sector tubes up to 20 bar without any evidence for leaks => fittings OK. • We have also tested one welded tube(1060) with laser welded fittings to 20 bar and no leaks were found => welding probably OK.

  9. Sectors Conclusion • Sectors with 1060 tubes might survive up to 16 bar but would have to test more sectors and with silicon(does silicon break?). Issue is potential for damage to other sectors. • If we go to work hardened 3003(we do the hardening by internal(up to 20 bar) and external pressure to flatten), then for sure no problems at 16 bar(or even higher). This is the safe way to go. • We have 3003 tubes on hand although they are a few mm shorter. Bending of these tubes started. • Laser welding looks OK. • Going to 3003 will cause some delay and some extra cost(for the additional laser welding). But looks like we can still meet schedule for delivery of sectors when production modules ready. • Sectors for system tests not affected – will use 1060 tubes. • Our plan is to proceed with 3003 tubing for production

  10. Reminder Disk Sectors Endcone Disk Rings Disk Frame Barrel Frame Endplate Disk Ring Mounts

  11. Disk Ring Fabrication Complete

  12. Dry Fit of 1st Disk Frame Section December 5, 2002

  13. Dry Fit of 1st Endcone December 5, 2002

  14. Global Support Status • No significant problems so far. • Bonding of 1st disk section this week, followed by 1st endcone before Xmas. • Most of parts for other sections ready or ready very soon. • Dry fit -> bond -> inspect other sections starting in January. • We remain on track to complete the fabrication by April 2003. • Understand by February Pixel Week need for center section of frame in Europe(and when). It must return to US for “trial insertion” of uninstrumented package into PST to be done at LBL.

  15. Miscellaneous Items • Custom “bolts” for mounting disk sectors to rings. • Delayed by work on sector tubes but will order in January • Disk ring mounts • Fabrication underway for delivery by mid-January • Tooling for drilling disk frames and inserting rings • Prototype completed long ago(with larger frame size) • Update delayed by work on PP1(and other parts of ATLAS). • Also realize will take some time to (re)survey rings with actual mounts. • Will be February before we start on drilling end section of frames.

  16. Other Laser Welding • Trials of capillaries just started yesterday. Yield(on 4 welds) only 50%, needs tuning – in progress. • Insertion of cables at PP0 greatly aided(only possible?) by making transition from 8mm to 4mm tubing outboard(larger Z) of PP0 connectors. 4mm pipes pass between connectors. • Laser welded various types of transition pieces to find best. Looks OK.

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