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(November 9, 2006)
The Second Right en Left box are ready for transport to CERN.
Two PT100's are glued in each
box and a Torlon coating (for electric isolation) is brushed on the inside.
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(August 17, 2006)
Chiel Bron finished welding of the second Left Detector Box.
********
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(may 8, 2006)
Chiel Bron is finishing the second RIGHT DETECTOR BOX
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(april 10, 2006)
LEFT AND RIGHT DETECTOR BOX:
LEFT DETECTOR BOX:
RIGHT DETECTOR BOX:
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(march 27, 2006)
Second box with the 4 side plates of 0.5mm pure AL and top foil 0.3mm AlMg3 is almost ready.
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(januari 19, 2006)
To solve welding problems the 4 side plates (before Almg3; 0.3mm) are replaced by 4 pure AL plates
with a thickness of 0.5mm. The top foil isn't changed (0.3mm AlMg3). The welds of the box are
succesfully done and Chiel is preparing to weld in the jig the thin box to the solid Al flange:
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(march 21, 2005)
Coating of the 'top' surface with a Getter coating at CERN
all pictures
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(april 6, 2004)
Welding of the top en side foils are succefully finished. The connection flange is welded on
the long side together with the box, to do are the two short ends
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(march 24, 2004)
Production of a second box is started, welding together of the top en side foils
is almost finished.
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(december 4, 2003)
The first Detector Vacuum Box is ready!.
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(november 19, 2003)
Top en side foils are welded together in the welding jig.
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(oktober 31, 2003)
Toblerone topfoil is welded together with the side plates (this is done in the welding jig).
The pictures below shows how Erno Roeland is welding the downstream front plate.
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(july 1, 2003)
Side foils of the box were succesfully formed at the VU.
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(december 19, 2002)
A new aluminium mold for 'hotgas Forming' (350 degrees) is machined at the Vu.
More 'toblerones' are added to increase the stiffness. The mold will be anodised.
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(november 20, 2002)
Buckling in the center toblerones is solved and ribs (2.5mm high) are added at
the forward-end to increase the stiffness.
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(oktober 24, 2002)
First nice foils is formed and He leak tested.
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(september 20, 2002)
First preparation are made for forming the 1:1 size foil.
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(april 10, 2002)
A thin layer of Poly-amide-imide is air brushed on the inside of the foil
for electrical protection.
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(march 26, 2002)
One final CuZn mold for Superplastic Forming is machined at the Vu:
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(january, 2002)
Three samples of the foil are viewed in a electron microscope:
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(december, 2001)
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(september, 2001)
Superplastic Forming process is started with a AlMg3 plate
During this techniques both the tooling and sheet are maintained at a
forming temperature typically between 470-520ºC.
Aluminium Superplastic Forming (SPF) is a hot stretching process in
which a sheet of superplastic grade aluminium alloy is forced onto
or over a single surface tool by the application of air pressure.
Two main forming techniques have been developed by Superform to cover
the large range of sizes and shapes applicable to the process:
Bubble forming and Cavity forming
Other Superplastic Forming website:
SUPERPLASTICITY on the WEB
| MOLD | first plate | detail first plate |
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(july 9, 2001)
A 0.3mm AlMg3 plate is shaped with 2 molds.
The maximum pressure in 2 is 60 Bar. the foil cracked at 65 Bar
on the 'sharp' edge. Between each pressure step the plate is a
annealed at 520 degrees Celsius. Radius=13mm.
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(june 25, 2001)
A 0.3mm AlMg3 plate is shaped with 2 another (composite) molds to get a smaller
radius in the corners.
The final pressure in Mold 1 was 105 Bar. In the mold 2 the foil cracked at 15 Bar
on the sharp edge. Between each pressure step the plate is a annealed at
520 degrees Celsius. Radius=3mm.
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(june 10, 2001)
A 0.3mm AlMg3 plate is shaped in 2 molds. Mold 2 is a new mold, a
negative of the Aluminium mold. In this new mold 2 the round shape is
beter supported and there is less local-tension on the sharp corner
so lower change to have cracks in this regions.
The final pressure was 95 Bar without cracks. To hold this high pressure
a new Pressure-Jig is build. Between each pressure step the plate
is a annealed at 520 degrees Celsius. The disadvantage is that this shape
is not reproducible. Radius=6mm
| New Pressure Jig |
Mold step 1 |
Mold step 2 |
Detail Mold 2 |
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| Foil outside |
Detail outside |
Foil inside |
Detail inside |
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(may, 2001)
A 0.28mm Al plate (purity 99.5%) is shaped in 2 molds.
Step 2 is done with many pressure steps from 10 to 19 Bar.
The final depth we get is 8.8mm (we need 9mm).
The min. thickness at some zones is 0.11mm, see pictures below:
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(april, 2001)
A 0.250mm Al 3004 plate (purity 99%) is shaped in 2 steps.
The first step formed the round shape, with 2 pressure steps
from 15 to 20 Bar.
Step 2 is done with many pressure steps from 10 to 32 Bar.
The final depth we get is 7.8mm (we need 9mm).
Between each step the plate is 20min annealed at 420 degrees Celsius.
Forming temperature is 20 degrees Celsius.
Plus point: no foldings in the middle round shape
| Mold step 1 |
Mold step 2 |
Foil step 1 |
|
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| Step 2: |
| inside view |
inside detail |
outside view |
outside detail |
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(okt, 2000)
The pure aluminum plate (0.25mm thickness is shaped with a pressure jig
into 12 steps (from 9 to 40 bar).
Between each step the plate is 20min annealed at 420 degrees Celsius.
| Chiel Bron | pressure jig |
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| inside view |
inside detail |
outside view |
outside detail |
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(march, 1999)
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| LINKS TO RELATED SITES |
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