WA-10413/11/2015

WELDING TESTS & OTHERS ISSUES

SUMMARYWA104 PROJECT

NEUTRINO EXPERIMENTS

1

Jean-Pierre Brachet Gilles FavrePaula FreijedoDidier Lombard

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INDEX• INTRODUCTION• PART 1: U-FRAME CORNER• STATUS OF THE WELDING CONFIGURATIONS • QUALITY LEVEL & NON-DESTRUCTIVE TEST (NDT)• STRATEGY FOR ASSEMBLY• TOOLING & MACHINING

• PART 2: EXTRUDED CORNER ASSEMBLY • STATUS OF THE WELDING CONFIGURATIONS FOR THE CORNERS TO PANELS• TEST PIECE VALIDATION• QUALITY LEVEL• WELDING OF THE U-FRAME TO EXTRUDED CORNER

• COMPONENTS DELIVERY

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INTRODUCTION

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The aim of this presentation is summarize and clarify some points related to the the different welding configurations and other issues for the Cold Cryostat WA104 in the frame of the Neutrino Experiment, in order to set up and qualify the best solution for manufacturing.

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STIFFENING FRAMES ALIGMENTS 1 To 5 – DRAWING: CEN104CR_0025

PART 2: EXTRUDED CORNER

PART 1: FRAMES CORNER

5

PART 1: U-FRAME CORNER

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1- WELDING CONFIGURATIONS

2 configurations for the U-Frame corner ACCORDING TO THE DRAWING CEN104CR_0026:

o Material: Aluminium EN AW-6082 T6o Thickness 20mm: MIG process (Details X1-X2-X5)o Thickness 10mm: TIG process (Detail X3)

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STATUS:- Configuration and parameters of the pWPS: VALIDATED- Welder qualification: On-going- Welding Procedure Qualification (PQR): On-going

MIG PROCESS-20mm OF THICKNESS:Drawing for Welding Qualification

Values taken during the tensile test of the PQR:- Tensile strength Rm= 220 & 226 MPa- Yield strength Re=

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TIG PROCESS-10mm OF THICKNESS

Drawing for Welding Qualification

STATUS:- Configuration and parameters of the pWPS: On-going- Welding Procedure Qualification (PQR) & Welder qualification: Next step

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2- WELDING OF A REAL CORNER Preliminary measurements of the Shrinkage on the real corner

3- QUALITY LEVEL & NON-DESTRUCTIVE TEST DURING PRODUCTION- The required quality level for welds imperfections shall be level B according to the standard EN-ISO 10042:2005- NDT & sequence:

1º- Radiographic test or Ultrasonic examination (100%) NOTE: US requires FLATENNING on the welds2º- Dye Penetrant NOTE: Defects reparation could be cause of CONTAMINATION

+/- 0.15mm

L=250mmL=350mm

+/- 0.1mm

ShringkageAverage 3.5mm Gap 10mm

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3- STRATEGY FOR ASSEMBLY

Fabrication the U piece whole with both corners welded:

NOTE: The DIMENSION of the panel SHALL BE ensured - REPEATABLE

PROPOSAL: Fabrication of the piece in 2 parts with only 1 corner welded

1 2

Cut and adjust the dimensions with the panel

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4- TOOLING

THE TOOLING FOR FRAME ASSEMBLY IS STORED IN THE BUILDING 156

- Mounting of the tooling to be done (Marzio’s team could be help) - The SCAFFOLDING is required

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5- MACHINING

Dedicated milling machine for the U-frame components will be installed in the building 156

Specific portable milling machine for chamfering have been developed

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PART 2: EXTRUDED CORNER ASSEMBLY

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1- WELDING CONFIGURATIONS FOR EXTRUDED CORNER TO JOIN THE PANELS Material: Aluminium EN AW-6082 T6 Process: MIG

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CERN TRIALS German proposal T15:

Results PRELIMINARY TEST:

T15 MACRO:- Penetration: 10.38mm (from the root to the surface)- Micro-Cracks[1001] at the root (red frame), not permitted according to the level B of NF-EN-ISO-10042.- Few gas porosity [2011] permitted according to the level B of NF-EN-ISO-10042 <1% melt area.

T15mag x100

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CERN proposal:

T14 MACRO:- Penetration 10.43mm (from the root to the surface)- Few porosity [2011] permitted according to the level B of NF-EN-ISO-10042 <1% melt area- Lack of fusion at the root [4013] not permitted according to the level B of NF-EN-ISO-10042

- T14Results PRELIMINARY TEST:

40º?

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2- TEST PIECE

The piece will be tested in order to validate the design:

3- QUALITY LEVEL & NON-DESTRUCTIVE TEST DURING PRODUCTION

The quality level and the different possibilities for NDT to perform on the welds should be checked.

4- WELDING OF THE EXTRUDED CORNER TO THE U-FRAME

The configuration for this joint will be discussed & defined

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COMPONENTS DELIVERED

U-FRAMES CORNERS By the end of this month

U- FRAMES BEAMS First batch availableSecond batch to be defined

ADDITIONAL EXTRUDED CORNER FOR TEST PIECES

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THANKS FOR YOUR ATTENTIONMERCI POUR VOTRE ATTENTION