Introduction to CERN Activities

Introduction to CERN Activities

2S Module meeting, 24 September 2012 Studies on module support inserts Refers to work by Riikka Hs, Helsinki Institute of Physics, summer student at CERN 2012 Heat Transfer Capacity of the 2S Module Support Insert Mechanical Strength of the 2S Module Insert Cooling Pipe Joints Reports available in https://espace.cern.ch/Tracker-Upgrade/2S-Module/Shared%20Documents/Forms/AllItems.aspx 2S module meeting, 24 September 2012, indico: 208421 1 Antti Onnela, CERN Heat Transfer Capacity of the 2S Module Support Insert 2S module meeting, 24 September 2012, indico: 208421 2 Antti Onnela, CERN Module support insert thermal analysis Module power estimates Power of a complete module [W] 2x8 CBCs 1.2 0.3 2 concenL-P GBT GBTIA GBLD Power trators converter 0.36 0.5 0.1 0.2 0.4 Power per support insert next to service board [W] 0.18 0.25 0.05 0.1

0.2 Power per support insert opposite to service board [W] 0.3 TOTAL 2.8 1.08 0.3 Insert material properties used Aluminium Epoxy Stainless steel CO2 2S module meeting, 24 September 2012, indico: 208421 3 Thermal conductivity, k Thermal conductivity, k Thermal conductivity, k Heat transfer coefficient, h 174 W/mK 0.2 W/mK 15.1 W/mK 10 000 20 000 W/m2K Antti Onnela, CERN Support insert geometry Cooling pipe dimension used: 2.2 mm OD, 2.0 mm ID (TOB single-sided rod type) In addition, a cap glued to surround the cooling pipe 2S module meeting, 24 September 2012, indico: 208421 4 Antti Onnela, CERN Module support insert thermal analysis Cases analysed: 25 25 30

30 35 40 mm mm mm mm mm mm long long long long long long insert, insert, insert, insert, insert, insert, h h h h h h = = = = = = 10 20 10 20 10 10 000 000 000 000

000 000 W/m K W/m2K W/m2K W/m2K W/m2K W/m2K 5.21 4.91 5.11 4.78 2 5.06 5.00 4.00 T / CT / C 1. 2. 3. 4. 5. 6. 5.40 6.00 Pipe CO2 Insert Glue Total 3.00 2.00 1.00 Total

Glue Insert CO2 Pipe 0.00 1 Case 1 2 3 4 5 6 2S module meeting, 24 September 2012, indico: 208421 5 2 Pipe 0.10 0.11 0.10 0.11 0.09 0.09 3 4 CO2 1.54 0.85 1.46 0.81 1.41 1.39 5 Insert 2.57 2.57 2.56 2.55 2.55

2.55 6 Glue 1.78 1.95 1.68 1.87 1.64 1.61 Total 5.40 4.91 5.21 4.78 5.11 5.06 Antti Onnela, CERN Module support insert thermal analysis Cases analysed: 1. 2. 3. 4. 5. 6. Case 1 2 3 4 5 6 25 mm long insert, h = 10 000 W/m2K 25 mm long insert, h = 20 000 W/m2K 30 mm long insert, h = 10 000 W/m2K 30 mm long insert, h = 20 000 W/m2K 35 mm long insert, h = 10 000 W/m2K 40 mm long insert, h = 10 000 W/m2K Pipe 0.10 0.11 0.10

0.11 0.09 0.09 CO2 1.54 0.85 1.46 0.81 1.41 1.39 Insert 2.57 2.57 2.56 2.55 2.55 2.55 Glue 1.78 1.95 1.68 1.87 1.64 1.61 Total 5.40 4.91 5.21 4.78 5.11 5.06 Conclusions: T over the assembly is ~ 5 C in all analysed cases Not excellent, as T within the module is estimated to be 5-7 C Reaching T of 10 C between module and coolant is difficult. CO2 heat transfer coefficient (h) has a significant impact More detailed studies needed to calculate h for different locations and loads along the rod, as well as finding the best suiting pipe diameter. Insert has a significant impact, ~ 50% of the T Increasing the insert length (mass) does not help much Shortening the distance between module and cooling pipe would help, but is geometrically difficult / impossible. Could we find another insert material, with higher thermal conductivity (> 174 W/mK), still low mass and

manufacturable? 2S module meeting, 24 September 2012, indico: 208421 6 Antti Onnela, CERN Mechanical Strength of the 2S Module Insert Cooling Pipe Joints 2S module meeting, 24 September 2012, indico: 208421 7 Antti Onnela, CERN Loads and properties Carbon-fibre frame: CTE: ~ 0. Stiffness: Very high compared to the thin-walled cooling pipe CTE difference between carbon-fibre frame and cooling pipe leads with T of 60 C to tension loads on the inserts: ~ 100 N with copper-nickel pipe ~ 125 N with stainless steel pipe Mechanical properties of the insert / cooling pipe assembly Aluminium Stainless steel Copper-nickel -6 CTE [1/K] 23.110-610-6 16.510-610 16.210-6 Modulus of elasticity [GPa] 70 193 152 310 600 800 380 590 Ultimate strength [MPa] (tensile) (tensile) (tensile) 120 - 550 at 300 at 0.2 % Yield strength [MPa] 280

0.5 % elongation elongation Elongation at break [%] 12 - 15 35 45 Araldite 2020 8.510-5 N/A ~ 15 (shear) N/A N/A The tension load could lead to detaching the cooling pipe from the insert, or detaching the insert from the carbon-fibre frame. 2S module meeting, 24 September 2012, indico: 208421 8 Antti Onnela, CERN Test assemblies Test assemblies made with 10 mm glue joint length 1. 2. The final connections are likely to be longer ! Four different test assemblies, 3 samples by type: Two geometries (images above) Two version of the glue joint Well glued joints Glue joints with Teflon coating on the cooling pipe (as used in the TOB) 2S module meeting, 24 September 2012, indico: 208421 9

Antti Onnela, CERN Test results Well glued With Teflon coated pipes Well glued broke in the pipe As expected, 10 mm glue joint stronger than the 0.1 mm walled pipe. Exception in one sample, where the glue joint broke completely. Not yet understood why. Teflon coated broke in the glue joint As expected and wanted 2S module meeting, 24 September 2012, indico: 208421 10 Antti Onnela, CERN Results and conclusions Well glued samples: Pipe broken Expected value Modulus of elasticity [GPa] Ultimate strength [MPa] Yield strength [MPa] Elongation at break [%] Maximum force [kN] 152 495 345 12 - 15 0.33 Teflon coated samples: Glue joint slipping Test results Average 142.83 498.50 464.39 15.76 0.33

7.70 13.94 0.01 6.97 0.15 Ultimate strength [Mpa] Maximum force [kN] Test results Average 353.28 62.13 0.23 0.04 Conclusions: Maximum load carried by the joints (0.33 kN, 0.23 kN) is higher than the load (0.1 1.3 kN) from the CTE differences between the carbon-fibre and the cooling pipe and T of 60 C. These need to be recalculated and tested when changing the pipe and insert dimensions (here old TOB cooling pipes and 10 mm glue joints were used). Will try understand why one well glued joint broke, whereas the pipe should have broken. Teflon in the tested glue joints acted, as wanted, as a fuse. In these samples 10 mm glue joint length. With longer glue joints, the Teflon connected joint will be stronger, the fuse effect wrt to pipe strength will not be very big Need to see if we want to pursue with this sliding cooling contact concept further or not. If yes, the choice of adhesive and Teflon needs to be carefully selected and tested. 2S module meeting, 24 September 2012, indico: 208421 11 Antti Onnela, CERN

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