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Some Recent BNL, LBNL and Yale Work

1. Honeycomb flatness from manufacturer

2. Commercially fabricated C-channel

3. VCR Fittings

4. BN powder thermal evaluations

5. Facing sample for electrical contact

D. Lynn, Local Support Vidyo Meeting Jan 23 2015

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Honeycomb Flatness

•Along with DESY and Liverpool BNL placed common order for new vented honeycomb

•BNL would like to investigate possibility to avoid grinding honeycomb. Need tighter tolerance on flatness. So BNL ordered two slices with tighter tolerance with of cost increase of about 6%.

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Honeycomb Flatness

•Ultracor gives the following conformance data. Measurements at 6 locations per slice.

•All measurements were within specification

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Honeycomb Flatness

• Spacing was 4” by 3”• Tolerance on both sheets within +/- .002” (50 um)•Can UK and DESY measure theirs?•Unfortunately all honeycomb slices were

deliberately oversized at 5.5 mm (to grind to 5.2 mm).•Do we make a slightly thicker stave to test concept?

• To compare, BNL made 35 measurements per slide in a grid pattern as shown below.

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Carbon Fiber C-Channels as Received from Allred/Dragonplate4 December, 2014

W. Emmet/T. HurteauYale University Physics Department

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Commercial C-channel

150 gsm-34 msi (aka 234 GPA)—700k tensile. 35% resin (Newport 301)

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End viewNote: this is untrimmed, machining end will clean this up

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Slight ridge at inside radius…tooling?

View of channel interior (legs facing camera)

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View of channel side 1

10View of channel exterior (legs facing away from camera)

Slight ridge here…tooling again?

11View of channel side 2

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Commercial C-channel

•Wall thickness E, F, G not the same, but uniform on each wall

• Large bow

•Will discuss with Dragon plate possible improvements

•Will try to irradiate parts with 25 MeV protons at Karlsruhe (pre/post bend test)

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Yale Brazing

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Yale Brazing Recipe

• Basically DESY recipe• Braze material: Wieland SCP-1 (68% Ag/5.0% Pd/26.6% Cu)• Brazed in vacuum furnace• Procedure:

• Vacuum at 10-5 mBar• Ramp up to 750 oC over 2 hours• Hold for 8 minutes at 750 oC• Ramp up to 820 oC over ~30 minutes• Turn off heat and allow to cool down under vacuum (take several hours)

• Whole process takes about a day• Sample also brazed at Solar Industries using same recipe

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Yale SS VCR to Ti Pipe Brazing

1A 1B

2A 2B

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Solar SS VCR to Ti Pipe Brazing

1A 1B

2A 2B

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First samples of Yale and Solar brazing had VCR fitting bore diameter about 1-1.5 thousandths larger the Ti pipe. Solar says want almost pressure fit to get a fillet

Both Yale and Solar samples were hydro pressure tested to 3500 PSI (~230 bar) for one day and showed no signs of leaking, i.e. no pressure change

Sent second small sample to Solar Industries; has approximately 0.5 thousandths larger diameter.

Full length Titanium tube will be vacuum brazed at Solar Industries following inspection/hydro pressure test of the second sample’s tighter-fitting VCR-titanium joints.

Titanium VCR Fittings

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Titanium VCR Fittings

At Sep 2014 ITK meeting Richard French asked us to look into whether Swagelok would make Titanium VCR fittings. In principle should be easier to braze to Titanium pipe. He was having difficulty with Swagelok contacts in the UK.

Will Emmet got first quote for Ti blind gland (we prefer blind gland so that we can drill gland to accommodate different diameter Ti pipes in case that dimension changes

First quote was for $466/each (similar to what Richard was getting).

Will used old contact to get quote down to $52 each.

We have ordered a quantity of 50. 15-16 week delivery.

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BN powder study

• Carl had mentioned they have access to an expensive machine that is designed to measure thermal conductivity; sorry, I don’t have the details at the moment.

• We decided it would be a good opportunity to use machine to compare the different BN powders currently in use.

• Graham also want to compare thermal conductivity with his device.

• Use 10%, 20%, and 30% BN powder (by weight).

• BNL/Yale: ZYP

• UK: Goodfellows

• DESY: PT140 (but we also obtained PT180…different particle size)

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BN powder study, sample list

BN Powder Percentage BN by weightLength Width Thickness Final Weight

For Carl [grams]1 ZYP 30 30 8.1 10% A 8.52 ZYP 30 30 8.1 10% B 8.63 PT140 30 30 8.1 10% A 8.64 PT140 30 30 8.1 10% B 8.65 PT180 30 30 8.1 10% A 8.86 PT180 30 30 8.1 10% B 8.87 GoodFellows 30 30 8.1 10% A 8.68 GoodFellows 30 30 8.1 10% B 8.69 ZYP 30 30 8.1 20% A 8.5

10 ZYP 30 30 8.1 20% B 8.711 PT140 30 30 8.1 20% A 8.612 PT140 30 30 8.1 20% B 8.513 PT180 30 30 8.1 20% A 8.714 PT180 30 30 8.1 20% B 8.915 GoodFellows 30 30 8.1 20% A 8.316 GoodFellows 30 30 8.1 20% B 8.417 ZYP 30 30 8.1 30% A 8.818 ZYP 30 30 8.1 30% B 9.119 PT140 30 30 8.1 30% A 8.720 PT140 30 30 8.1 30% B 8.921 PT180 30 30 8.1 30% A 9.122 PT180 30 30 8.1 30% B 9.223 GoodFellows 30 30 8.1 30% A 924 GoodFellows 30 30 8.1 30% B 8.8

For Graham25 ZYP 20 20 1.5 10% 0.726 PT140 20 20 1.5 10% 0.727 PT180 20 20 1.5 10% 0.728 GoodFellows 20 20 1.5 10% 0.729 ZYP 20 20 1.5 20% 0.730 PT140 20 20 1.5 20% 0.731 PT180 20 20 1.5 20% 0.732 GoodFellows 20 20 1.5 20% 0.733 ZYP 20 20 1.5 30% 0.834 PT140 20 20 1.5 30% 0.735 PT180 20 20 1.5 30% 0.836 GoodFellows 20 20 1.5 30% 0.7

Size [in millimeters]

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BN powder study

Samples to ship week of Jan 26th

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Electrical Aspects of CF Facings

• Want to test transverse and vertical electrical connectivity• Want to test co-cured foil to facing electrical connectivity

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Samples Made at LBNL; testing to start soon(quick test showed good DC connection of foil to fibers