n TOF target #3 Production readiness review …...• Ultrasonic testing before insert machining to reveal bulk defects • Inspection carried out the 29/04/19 • Sensibility of defects

n_TOF target #3 Production readiness review – Prototyping activities & manufacturing aspectsMarc Timmins EN/MME, Vincent Maire EN/MME, Thibaut Coiffet EN/MME, Josep Busom EN/MME, Mark Butcher EN/SMM.

29th of May 2019

n_TOF target #3 PRR 29-05-2019

Outline

2

• Overview of challenging designs

• Moderator and Bi-metallic transition

• Vessel

• Tests and inspections

• Anti creep plate

• Instrumentation

• Mounting procedure


Challenging designs

3

Anti-creep

platesBi-metallic transition

Thermo-

couples


4

Moderator and Bi-metallic transition

Deep milling for central insert Ø40 over

300mm (minimising deformations)

H. Moderator

Insert

Body

EB welding



5

Precise machining of interface

for EB weld on insert

(Localisation 0.1mm).

H. Moderator


6


Body machined according

to metrology on insert to

achieve a perfect fit for EB

weld. Maximum tolerated

gap: 0.1mm

H. Moderator


7


Extra thickness to be machined according to metrology

on vessel to achieve maximum gap of 0.1mm

Extra

thickness

Vessel interface

H. Moderator


8


Production strategy:

1. Production of full scale prototype at CERN has started.

2. Insert has been produced and is conform. (See part)

3. EB Welding tests will start in September 2019.

4. Body machining and final EB welding assembly at CERN in 3rd trimester 2019.

5. If successful the moderator will be used in final target.

• Conforms in terms of dimensional tolerances

• Passes vacuum and pressure leak tests.

• inspections conformity (Visual, X-ray, PT)

H. Moderator


9


H. Moderator insert considerations• Material EN AW-5083 H111

• 2 products were considered

• 3D forged plates: Most isotropic properties and random distribution of

precipitates (Mg and Si based). Non-standard products Uncertain

supply delays and cost

• Rolled plates: Anisotropic properties and precipitates aligned in the

rolling direction Readily available products

H. Moderator Insert prototype Material: 3x rolled plates of EN AW-5083 H111, due to material availability

• Dimensions:

• 3x: 650 mm x 650 mm Moderator insert fabrication (1x) and spares (2x)

• 2x: 200 mm x 300 mm Material qualification (1x) and machining /

welding qualification (1x)

• Certificates: Specific inspection (type 3.1) certificate from supplier, concerning

mechanical properties and chemical composition

H. Moderator material considerations


10

Material qualification for prototype :

Inspection at CERN (ongoing)

• Ultrasonic testing before insert machining to reveal bulk defects

• Inspection carried out the 29/04/19

• Sensibility of defects equivalent to Flat bottom hole (FBH) of 1.2 mm

• Inspection was conform plate shipped for machining

• Metallographic inspection:

• Reference microstructure images, specifically from the precipitates, for

corrosion considerations

• To be compared with 3D forged Al plates

LD 200x

100 µm

ST 200x

100 µm

Moderator and Bi-metallic transitionH. Moderator material considerations



11

Bi-metallic transition


12


Following the leak detected in the bi-metallic transition used

to test the vertical moderator prototype in 2018 (EDMS-

1995057)

Moderator

side

Vessel

side

28mmNew design with 28mm bi-metallic

transition wall thickness

Other materials proposed

but ruled out.

Copper, (not good for

galvanic coupling with Al).

Nickel (ferromagnetic)

Bi-metallic transition


https://edms.cern.ch/document/1995057/1

13

Moderator and Bi-metallic transitionProduction of a bimetallic transition prototype• Supplied by NEYCO See certificates (EDMS-2068498) and UT-PT

inspection at CERN (EDMS-2047350, EDMS-2080662)

Vacuum and pressure

tests EDMS-2143635 :

Machined in steps of 5mm

down to final thickness of 8mm

No leak detected:

PT at the bimetallic

transition, for inner and

outer surfaces was

conform, no delamination

observed

Resulting

specification

EDMS-2150802







Vessel

14

No prototypes will be produced however all welds will be

qualified carrying out tests on samples followed by UT&PT


15

Vessel Assembly process


16

VesselTIG lip weld

(After insertion of the target)

EB Butt

weld


Step

machined

after welding

x-ray VT UT PT Comment

W01Wedge support to

vessel EB

Butt

weld304V/316L Yes

Existing

WPQRYes Yes Yes No Yes

Before and after

having machined the

step

W02.1

W02.2

W03 Vessel Long. Weld TIGButt

weld316L/316L Yes

Existing

WPQRYes Yes Yes Yes Yes

W04Bi-mellic transition to

vesselEB

Butt

weld316L/316L Yes

Existing

WPQRYes Yes Yes Yes Yes

Before and after

having machined the

step

W05H moderator to bi-

metallic transitionEB

Step

Butt

weld

5083H111/5

083H111No

Based on

representative

samples

Yes No Yes No Yes

Unable to locate

spikes with x-ray nor

with UT

W06.1

W06.2

W07Vessel front plate to

vessel bodyTIG

Edge

weld316L/316L No Existing

WPQR Yes No Yes No Yes

W08feedthrough to front

plateTIG

Corner

weld316L/316L No

Existing

WPQRYes No Yes No Yes

W09.1

W0.9.2

B01Thermoucouple to

feedthrough

Vacuum

brazing

Inconel/

316LNo

Based on full scale

PrototypeYes No Yes No Yes

E01 Bi-metallic transitionExp.

Bonding

5083/Al-

1050/TiG1/3

16L

No

Based on

reprenstative

Prototype

Yes No Yes Yes Yes

PT from inside before

welding moderator.

From outside after

welding moderator.

YesNo PT on Iner weld

Weld

typeMaterial

Standard

pressure weldQualification process

Weld

numberDescription

Weld

process

Ve

sse

l

pressure/Va

cuum test

No Yes

Final inspection

n_TOF target #3 Weld qualifications and tests

YesNo PT on Iner weld

YesExisting

WPQRYes

316L/316LFeadthrough tube to

front plateTIG

Corner

weldYes

N2 outlets to vessel TIGCorner

weld316L/316L

N2 tube to Front plate TIGCorner

weld316L/316L Yes

Existing

WPQRNo

No Yes

Existing

WPQRYes No Yes

17

Qualification

process

Pressure &

vacuum test

Final inspection

(x-ray, visual, ultra-

sound, dye penetrant

Tests &

inspection

n_TOF target #3 PRR 29-05-2019 100%

Tests &

inspection

18

Particular care must be taken for qualifying joints which are limited in

terms of inspections (ex: Unable to locate spikes in the weld W05).

Spike

defect


Step

limit

Ste

p

limit

Spike

defect

Transverse

Longitudinal

x-ray VT UT PT Comment

W10Moderator nozzles to

bodyEB

Step

Butt

weld

5083H111/5

083H111No

Based on

representative

samples

Yes No Yes No Yes

W11

Bi-melallic pipe

transition H&V

moderator

TIGButt

weld

5083H111/5

083H111Yes

Existing

WPQRYes Yes Yes No Yes

W12.1 Yes Yes Yes

W12.2 No Yes Yes

W13.1 Yes Yes Yes

W13.2 No Yes Yes

W14Vertical moderator to

moderator supportEB

Edge

weld

5083H111/5

083H111

Existing

WPQRNo No Yes No Yes

n_TOF target #3 Weld qualifications and tests

Weld

numberDescription

Weld

process

Weld

typeMaterial

Standard

pressure weldQualification process

pressure/Va

cuum test

Final inspection

No

No

Unable to locate

spikes with x-ray &

only partly with UT

Unable to locate

spikes with x-ray &

only partly with UT

No5083H111/5

083H111

Based on

representative

samples

Based on

representative

samples

Yes

Yes

No

Mo

de

rato

rs

H moderator insert to

body

V moderator insert to

body

EB

Step

butt

weld

EB

Step

butt

weld

5083H111/5

083H111

19

Inspection

unable to locate

spikes in W13.2

and W12.2 and

W10

Tests & inspection


Anti creep plate

20

F

F

20mm x 4mm grooves

580 x 620mm

Material

Al 6082 T6

Machined from both sides

on vacuum table for

limited deformations and

controlled thickness.

Pb Pb


Anti creep plate

21

Prototype


Instrumentation

22n_TOF target #3 PRR 29-05-2019

23

Instrumentation

Non-broken

Non-broken

Broken

Broken

Induction brazing failed. Inconel sheath melded on one of the probes. Surprising

the probes still work and the feedthough is leak tight. However new brazing will

be carried out in a Furness at 850oC.


Mounting procedure – Pb slices

24

Discussion ongoing with MTH (Pb

producer) to find best way of installing Pb

blocks inside the anti-creep cradle.

Challenges:

- Handling the Pb blocks without drilling

holes or using inserts.

- Mounting the thermocouples inside the

anti-creep plates while installing the Pb

blocks.

- Securing position of Pb block during

mounting.


Mounting procedure

25n_TOF target #3 PRR 29-05-2019

26

Mounting procedure


27

Mounting procedure


Thankyou for your attention

Questions ?

Documents

n TOF target #3 Production readiness review …...• Ultrasonic testing before insert machining to reveal bulk defects • Inspection carried out the 29/04/19 • Sensibility of defects