LHC experiments C Garion TEVSC Outline C Garion Material requirements amp choice Design EJMA and Manufacturing requirements Mechanical bellows properties Manufacturing process Tests ID: 1006419
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1. C. GarionAluminum bellows for LHC experimentsC. Garion, TE/VSC
2. OutlineC. GarionMaterial requirements & choiceDesignEJMA and Manufacturing requirementsMechanical bellows propertiesManufacturing processTestsStatus and next stepsConclusion
3. C. GarionMaterialRequirements:Formability (high ductility)Weldability (also with 2219)Low Heat affected zoneAvailable in thin foilsGood mechanical properties at elevated temperatures (>180 C)5083 H111, 0.2 and 0.3mm thick, 200 mm widthWeld reliability
4. C. GarionDesignAlgorithm of optimization of bellows expansion joints (Based on EJMA)Minimise the objective function: inequality constraints: bellows convoluted length inner diameter outer diameter bellows maxi compression membrane stress membrane stress membrane & bending stress fatigue life column buckling in-plane squirm Atlas constraints (technical specification EDMS 429891):Lbmax = 100 mmDmin ~ 60 mmDmax = 80 mmStroke = -24/+8mmNf > 500 cycles
5. C. GarionDesignManufacturing requirementsPlastic strain during forming process Forming at elevated temperature required
6. C. GarionDesign13 convolutions, bellows length: ~96mm, Inner diameter: 60 mm, outer diameter: 80 mm
7. C. GarionDesignBellows properties – FE modelForce/displacement curveElastic-plastic buckling analysisPlastic and total strain fields+ Manson Coffin equation: Fatigue life estimationFE model
8. C. GarionBellows manufacturing process(courtesy of L. Prever Loiri, EN/MME)Aluminum foilRolled tube & longitudinal weld (EB)Welds of the end fittings (EB)Forming @242°C combining pressure and displacement loadingCut of the end fittingsCleaning with phosphor nitric acid [VSC/SCC] Optimization of the temperature distribution Automatic displacementLeak test after “bake out”
9. C. GarionBellows manufacturing processSome Pictures (EN/MME)Tubes equipped with the end fittingsTubes and pressure systemDie systemForming system
10. Tests (courtesy of H. Rambeau)C. GarionFatigue testsPrototypeSeries 1Series 2RT<N>=2300<N>=19503019150 C<N>=1000200 C1185250 C193All bellows with welding defectsCollapse of the convolutions @ 250 C
11. C. GarionStatus and next stepsATLAS (VA chamber): Bellows manufactured Fatigue life qualification done and will be continued Tests on NEG coating ongoingLHCb: Z=2800, same bellows as ATLAS VA, design of compensator to be redone UX85-2/3: design done (limitation by the sheet width) forming tooling being manufactured/assembled first tubes doneCMS (End cap pipe compensator): Under consideration
12. C. GarionConclusionDesign and manufacturing of aluminum bellows are mastered.Aluminum bellows are suitable and have been qualified for UHV applications.Bellows are qualified for a temperature of 200 C.Bellows for ATLAS VA chamber are ready for installation (after leak test).Manufacturing of the bellows for LHCb are in progress.
13. C. GarionRT150 C200 C250 CTensile curves0.3 mm, RD
14. C. GarionS-N curveFatigue of deep rolled AlMg4.5Mn (AA5083) in the temperature range 20–300 ◦C, P. Juijerm et al., Materials Science and Engineering A 379 (2004) 286–292