Stave Core QC

Peter SutcliffeRAL 24th Sept 2014

QA RAL 2

R-Phi Bus tapeCo-cured to Carbon Skin

EOS Closeout

Cooling Tube Assy

Stereo Bus tapeCo-cured to Carbon Skin

Allcomp foam Cooling strips

Honeycomb core

Carbon C Channels

Allcomp foam End cooling

Z=0 Closeout

Outline and Stave Detail

25/09/14

• Very few changes since Freiburg, mainly in the SMC cooling block area• Drawings are available here https://twiki.cern.ch/twiki/bin/view/Atlas/UKThermoMECHDocs

currently being used for the stave toolingo Looking to upload to EDMS

• Areas that need to be looked at are the tolerances eg flatness of the stave, twist in the ‘C’ channels

QA RAL

Stave Construction and Materials

25/09/143

• Stave is manufactured from 2 UD Carbon and kapton face sheets with a core manufactured from Ultracor Honeycomb and Allcomp Foam

Component Material Remarks

Carbon Face sheet

Tencate K13C2U45g/m2 EX1515 Resin

3 layers 90/0/90 total thickness 0.15mmCo-cured onto a kapton bus, thickness 0.2mm

Honeycomb Core

Ultracor Carbon HoneycombUCF-126-3/8-2.0

Final thickness 5.2mm

Carbon Foam Core

Allcomp K9 Final thickness 5.2mm

Cooling tube Titanium CP3 2.275 x 0.125 wall

End Closeouts PEEK CF30

C Channels Carbon Fibre

Honeycomb core

Carbon foam

C Channel Face sheet Bus tape

QA RAL 4

Quality Assurance- Quality Control

Quality Assurance• Proactive• R and D to determine:

– Tooling design– Gluing techniques– Good manufacturing practice– Written procedures,

consistency with manufacture– Cleanliness– Tolerance selection– ….

Quality Control• Reactive

– Inspection techniques– Inspection procedure. When to

physically inspect eg after each operation• Inspection ‘stamp’ after each

operation – more likely a database.– CMM, non contact, ESPI

• Checking tolerances-flatness, parallelism

– Visual inspection– Identifying defects and assessing

concessions– Repair procedure

25/09/14

Forum on Tracker Detector Mechanics - Hamburg, 2014

5

Plank #9 flatness and stiffness

01/07/14

• Flatness is around 0.20 and a twist has been shown. Not as good as we would like although the overall thickness is very uniform, proving the CNC machining of the core works.

• Bending stiffness of the planks made so far.

QA RAL 6

How flat can we make the stave?What tolerance to have?

25/09/14

QA RAL 7

Locking points

25/09/14

Need to specify ‘twist’ in the locking points

QA RAL 8

Stave Geometry

Critical Dimensions:• Overall Length 1277• Width 115• EOS at Z=0 to Silicon Edge 0.1mm• Module to Module Gap 0.46mm• Pitch of Modules 98mm

25/09/14

R Phi Side

Stereo Side

XY dimensions ofFiducials needs defining