1

BAM Activity at CERN

New welding tools

Alternative folding brick: dimension measurements

Leakage test measurements in destructive mode

Pressure test measurements on pile

Outlooks

S. Buontempo, G. Decreuse, J. Dupraz, C. Schillinger

OPERA Collaboration meeting LNGS, May 20th , 2003

2

New welding tool from Sidec firmManual welding clamp with 2 heating sides and possibility to adjust: - welding heating time, - welding cooling timepressure depends from operator

Welding machine with 1 heatingside, with vacuum chamber and Possibility to adjust: - welding heating time, - welding cooling timepressure is fixed at 1 bar

3

Modified welding tool

We modified the manual welding clamp andnow we can control and adjust the pressure and start with external switch:• the closure of clamp (at set pressure),• the welding (heating of the clamp), • the vacuum (with slow ramping).

4

Modified welding tool

The possibility to adjust welding parameters has showed us that we have the best welding performance working at:

• 2 sec heating time• 6 sec cooling time• 5 bar pressure on the clamp

We have performed preliminary test measurements on envelopes done with different laminate films (Nagoya, Sidec FA30, Sidec 122TLS95), with T and without T points.

5

New welding toolWith the possibility to perform vacuum in a chamber we have checked the performance of welding inside vacuum environment.

The welding clamp here is heating on a single side and the opposite one is a silicon strip.

The pressure is 1 bar (not adjustable) and wehave found the best welding conditions at

1.2 sec heating time 2 sec cooling time

We are in contact with Sidec firm to applychanges on these welding conditions

6

Alternative folding packaging

We know that the weaker part of the ECC packaging with laminated film is the zone with overlapping of two welding lines (so called T point)

Some of the pre-selectedfirms have proposed anAlternative packagingwithout T point.

7

Alternative folding packaging

This kind of packaging can be done with several configurations having:

- different positions of the folded parts,

- and/or different positions of welding lines

8

Alternative folding packaging

After some brain storming we have chosen the following configuration to start measurements:

Folded parts on side and bottom

Welding lines on top and sides

9

Alternative folding packagingPreliminary measurements on the new brick shape:

Brick high

Brick length We made a tool to pull the

laminated film while welding in order to minimize the extra material on the corners

10

Alternative folding packagingMeasurements on 2 Al bricks wrapped with 0.2 mm PE film (nominal high 103.5mm):

Pos. brick n.1 n.2

1 -149 +1512 +64 +264 3 +426 + 5674 -158 +1525 +254 +5186 +528 +650

123456

We have seen that points2, 3, 5, 6, reduce with pressure (there is air gap therein the folded parts)VERY PRELIMINARY

11

Alternative folding packagingMeasurements on 2 Al bricks wrapped with 0.2 mm PE film (nominal high 125 mm):

Pos. brick n.1 n.2base

1 +158 +1512 +305 +053 3 +380 - 096top

4 +720 +3205 +1470 +15406 +440 +130

123

456

We could partially compensate this by skates and by PE, 0.2 mm thinner that carton paper

VERY PRELIMINARY

Points 4, 5, 6, reduce with pressure (air gap there in the folded parts)

12

Leakage measurements: set upStep 1: we make a brick with Al block or real pile, we packed with carton (or PE) and laminated film under vacuum, and then we make a hole

Step 2: we make vacuum again inside the brickusing the mass spectrometer pump

Step 3: we inject He around the brick and seethe amount measured by the mass spectrometer

13

Leakage measurements: materials and configurations

We have performed test measurements on different configurations:• envelopes (with T and without T)• Baseline bricks with carton or PE inside• Baseline no T bricks with carton or PE inside

We have used different materials:• Laminated films - Sidec FA30, Sidec122TLS95 (softer than FA30 with same low gas permeability), Nagoya film• Inside wrapping - Carton paper and PE

All test measurements have been performed with 5 min measurement time on mass spectrometer

14

Leakage measurements: results

Sidec 122TLS 95 Envelopes (no T) with 0.2 mm PE film inside

2.20E-10

4.90E-10

7.70E-10

2.50E-10

4.90E-10

9.20E-10

2.70E-10

2.70E-10

4.10E-10

4.30E-104.30E-104.90E-10

3.00E-10

2.70E-10

4.30E-10

5.60E-10

4.30E-10

5.20E-10

0.00E+00

1.00E-10

2.00E-10

3.00E-10

4.00E-10

5.00E-10

6.00E-10

7.00E-10

8.00E-10

9.00E-10

1.00E-09

1 2 3 4 5 6 7 8 9

This shows that we have a good control of welding procedure and thatlaminated film is high quality

15

Leakage measurements: resultsAL bricks done in baseline mode (with T) with Sidec laminated film 122TLS 95 and carton paper

Sidec TLS95 + white carton

3.40E-10

5.20E-10

6.50E-10

4.50E-10

4.10E-10

4.80E-10

6.30E-10

3.90E-10

4.00E-104.40E-10

2.90E-10

8.90E-10

9.80E-10

5.80E-10

5.10E-10

5.30E-10

4.40E-105.10E-10

5.60E-10

7.20E-10

0.00E+00

2.00E-10

4.00E-10

6.00E-10

8.00E-10

1.00E-09

1.20E-09

1 2 3 4 5 6 7 8 9 10

Bricks

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Leakage measurements: resultsAL bricks done in baseline mode (with T) with Sidec laminated film FA30 and carton paper

Sidec FA30 + black carton

3.10E-09

1.20E-09

4.70E-103.00E-10

1.90E-103.10E-102.70E-10 3.10E-10

9.80E-10

1.90E-10

5.20E-10 5.20E-10

3.50E-104.30E-10

3.60E-10

1.00E-09

3.60E-10

5.90E-10

0.00E+00

5.00E-10

1.00E-09

1.50E-09

2.00E-09

2.50E-09

3.00E-09

3.50E-09

1 2 3 4 5 6 7 8 9

Bricks

FA30 is also good in terms of permeability but it is mechanicallyharder than 122TLS95 giving worst brick shapes

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Leakage measurements: resultsEnvelopes done with Nagoya film and carton

leakage rate in envelopes

0.00E+00

1.00E-10

2.00E-10

3.00E-10

4.00E-10

5.00E-10

6.00E-10

7.00E-10

8.00E-10

9.00E-10

1 2 3 4 5 6 7 8 9 10

envelope

lea

ka

ge

ra

te (

mb

ar.

l/se

c)

envelopes with T

0.00E+00

2.00E-10

4.00E-10

6.00E-10

8.00E-10

1.00E-09

1.20E-09

1.40E-09

1.60E-09

1 2 3 4 5 6 7 8 9 10

envelope

lea

ka

ge

ra

te (

mb

ar.

l/se

c)

No T with T

No Leakage

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Leakage measurements: resultsAL bricks done in baseline mode (with T) with Nagoya film and carton

Nagoya + black carton

3.20E-102.50E-102.30E-102.40E-10

3.40E-103.40E-103.10E-10

7.20E-09

2.20E-08

1.00E-08

8.00E-07

3.40E-08

1.00E-08 1.10E-08

1.00E-10

1.00E-09

1.00E-08

1.00E-07

1.00E-06

1 2 3 4 5 6 7

Bricks

Important leakage in T point (confirming preliminary data reported in Strasbourg meeting)

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Leakage measurements: resultsAl bricks done in baseline mode (with T) with Nagoya film (starting from envelopes done by GRT firm) and carton

GRT enveloppe (film Nagoya)

6.40E-10

8.30E-10

3.80E-104.50E-10

5.40E-10

8.20E-10

4.10E-10

6.60E-106.20E-10

1.20E-09

0.00E+00

2.00E-10

4.00E-10

6.00E-10

8.00E-10

1.00E-09

1.20E-09

1.40E-09

1 2 3 4 5

Bricks

Much lower leakage (on envelopes 2 of 3 welding lines are done in industrial mode with larger welding line and with a rolling device)

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Leakage measurements on a real pile brick

Pile bricks done in envelope mode (no T) with Sidec film 122TLS 95 and PE (replacing carton)

leakage rate vs time

0.00E+00

5.00E-10

1.00E-09

1.50E-09

2.00E-09

2.50E-09

3.00E-09

3.50E-09

4.00E-09

4.50E-09

0 50 100 150

time (min)

Le

ak

ag

e r

ate

(m

ba

r.l/s

)In first 30 minthe mass spectrometer measures a leak

After 135 min we find no leakage even with He injection.So the brick did not leak, but there was residual air inside

No He injected

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Leakage measurements: conclusionsEnvelopes: we do not find big difference in between T and no T modefor all tested laminated films. In empty envelopes there is not the mechanical stress on T point like in bricks

Al Bricks: - with all Sidec films we find low leakage 5 x 10-10 (new 122TLS95 is much better in terms of mechanical flexibility)- with Nagoya film we find large leakage 1 x 10-8 in T point- using Nagoya film envelopes done by GRT firm we find low leakage ~7 x 10-10

Pile brick:Preliminary measurement (lack of material !) show that the pile traps air inside which demands for 30 min to be purged out.Further study is needed on pressed piles

22

Pressure test measurements on pile

Some of the pre-selected firms have raised the problem of residual air inside the pile. They propose to purge it applying pressure.

We have started some test measurements with hydraulic pump withpressure range up to 700 kg/cm2

23

Pressure test measurements on pileIn order to evaluate the pile squeezing we performed a differential measurement with respect to the deformation of the table of the machine,raising up to 100 kg/cm2

pressure pile table differencekg/cm 2̂ mm mm mm

10 -1,37 -0,9 -0,4725 -1,5 -1 -0,550 -1,7 -1,12 -0,5875 -1,87 -1,22 -0,65

100 -2,09 -1,33 -0,760 -0,42 0 -0,42

25 -1,48 -1 -0,4850 -1,7 -1,14 -0,5675 -1,88 -1,25 -0,63

100 -2,06 -1,34 -0,720 -0,45 0 -0,45

100 -2,06 -1,34 -0,72here we apply the adhesive tape

70 -1,8 -1,22 -0,580 -0,43 0 -0,43

pile squeezing

-2.5

-2

-1.5

-1

-0.5

0

0 5 10 15 20

pressure (kg/cm2)

dis

pla

ce

me

nt

(mm

)

pile

table

difference permanent reduction, lost since the beginning,

confirmed even after wrapping with adhesive tape

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Pressure test measurements on pilePerforming the test we learned the following information

Applying pressure ~ 100 kg/cm2 the pile (or parts of it) get sticky. This may depend from the:

• vacuum sucking effect of removing air,• residual lamination oil,• painted lead,• stickiness of emulsion films

This could help the BAM procedure but wehave to evaluate if it is dangerous for emulsion sheets.

We need to repeat these tests with final lead and emulsion sheets

25

Pressure test measurements on pileWith pile under pressure (70 kg/cm2) with - 0.58 mm squeezing effect we wrapped it with adhesive tape (as proposed by some firms):

3M R425 XT-8015 (0.13 mm Al with siliconglue, certified zero degassing)

This could replace carton or PE in baseline option or could be a hermetic and light tight packaging on top of which we can apply mechanical pressure (alternative solution)

…moreover

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Pressure test measurements on pileAfter wrapping the pile goes back to - 0.43 mm squeezing and

it becomes “solid” !

This could also simplify a lot all the pile manipulationduring the BAM procedure before packaging

We need to repeat these tests with final lead and emulsion sheets

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BAM Activity at CERN: Conclusions and OutlookNew welding devices have been received and modified.

More experience has been done on welding procedure and leakage rate measurements.

A new laminated film 122TLS95 from Sidec has been testes: positive results in terms of leakage. Sidec firm is producing a customized 122TLS95 film with addition of PE photo black inside and aluminized PE outside. Delivery expected in mid june.

We have started studies on Brick packaging with no T point.Preliminary measurements on dimension show an increasing of brickHigh and length. More precise evaluation is needed for more statisticand possible sources of compensation (skate shape, PE replacing carton etc etc)

Preliminary study of pile compression have started.

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Additional measurements needed on:• on brick size, (baseline T and no T, with new laminated film and alternative packaging)• on pile bricks in destructive mode (Pb and emulsion urgently needed)• using final laminated film solution (custom for OPERA from Sidec)• performing He injection in the brick • on leakage rate in non destructive mode

Alternative packaging film tests: mechanical performance, ECC dimension uniformity, performance of wrapping with adhesive tape,pressure measurements on pile

Welding: test on new tools, modifications on vacuum chamber machine to apply same conditions on modified manual clamp

BAM firm selection: test measurements on packaging material compatibility with emulsion films and follow up of BAM proposed designs

BAM Activity at CERN: Conclusions and Outlook