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
n_TOF target #3 PRR 29-05-2019
Challenging designs
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Anti-creep
platesBi-metallic transition
Thermo-
couples
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Moderator and Bi-metallic transition
Deep milling for central insert Ø40 over
300mm (minimising deformations)
H. Moderator
Insert
Body
EB welding
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Moderator and Bi-metallic transition
5
Precise machining of interface
for EB weld on insert
(Localisation 0.1mm).
H. Moderator
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Moderator and Bi-metallic transition
Body machined according
to metrology on insert to
achieve a perfect fit for EB
weld. Maximum tolerated
gap: 0.1mm
H. Moderator
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Moderator and Bi-metallic transition
Extra thickness to be machined according to metrology
on vessel to achieve maximum gap of 0.1mm
Extra
thickness
Vessel interface
H. Moderator
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Moderator and Bi-metallic transition
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
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Moderator and Bi-metallic transition
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
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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
n_TOF target #3 PRR 29-05-2019
Moderator and Bi-metallic transition
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Bi-metallic transition
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Moderator and Bi-metallic transition
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
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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
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Vessel
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No prototypes will be produced however all welds will be
qualified carrying out tests on samples followed by UT&PT
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Vessel Assembly process
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VesselTIG lip weld
(After insertion of the target)
EB Butt
weld
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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
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Qualification
process
Pressure &
vacuum test
Final inspection
(x-ray, visual, ultra-
sound, dye penetrant
Tests &
inspection
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Tests &
inspection
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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
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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
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Inspection
unable to locate
spikes in W13.2
and W12.2 and
W10
Tests & inspection
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Anti creep plate
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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
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Anti creep plate
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Prototype
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Instrumentation
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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.
n_TOF target #3 PRR 29-05-2019
Mounting procedure – Pb slices
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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.
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Mounting procedure
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Mounting procedure
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Mounting procedure
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Thankyou for your attention
Questions ?