Thermal Shield Connection Study Niklas Templeton 150216 Thermal

Thermal Shield Connection Study Niklas Templeton 15/02/16

Thermal Shield Connection Study • Updated connection configuration • FE Model • Steady State Thermal Results • Welded shield • Pipe with integrated connection • Separate connection • Al 6061 Pipe • SS 316 Pipe • Static Structural – Thermal Contraction • Pipe and Panel Stress Comparison

FE Model – Connection Proposal 9 Lateral Fixed connection points (100 mm long) 2 Floating clamp connections for FPC thermalisation Top circuit modified for assembly purposes FPC load applied directly to clamp HOM Coax heat load applied at Panel Interface

Boundary Conditions • Heat Loads: see table • Pipe 50 -70 K Gradient • Radiation: 1. 7 W/m 2 Flux applied all external surfaces • Titanium Fixations: T=295 K at OVC interface • Material Properties: see graph • All thermal contact connections: 200 W/m 2 K (unless otherwise stated) for conservative results • Assuming no contact between pipe and panels other than at connection points Intercept Heat Load (W) FPC 55 HOM Coax 12. 0 Blades 7 Tuner 5 CWT 1 Qty 2 6 4 2 2 Total (W) 110 72 28 10 2 222

Welded Connections Pipe Connection Welded Shield Thermal Gradient T min (K) T max (K) 50. 3 90. 1 Ideally bond between Pipe-Fillet & Fillet-Panel Conclusions: • T max is concentrated at HOM Coax 6, can be improved. • Results are promising • Connection configuration to be carried forward • Ease of manufacture & assembly • Shield not over-constrained

Connection Comparison 1. Welded Connection 2. Integrated Connector* Ideally bond between Pipe-Fillet & Fillet-Panel Contact resistanc between Connector-Panel 3. Separate Connector Al Pipe* 4. Separate Connector SS Pipe* Contact resistance between Pipe-Connector & Connector -Panel 2. *Contact area scaling factor required Estimated as 1: 3

Thermal Contact Conductance 167 W/m 2 K 250 W/m 2 K 500 W/m 2 K Thermal Contact Resistance Measurements for indirectly cooled SR Optics, B Fell & K Fayz, Daresbury Laboratory 2013

2. Integrated Connector 666. 7 W/m 2 Contact resistanc between Connector-Panel Shield Thermal Contact Scaled Thermal Gradient Conductance Contact Conductance (W/m 2 K) T min (K) T max (K) Welded 50. 3 90. 1 2000 666. 7 58. 8 96. 4 1500 500. 0 61. 4 98. 4 Integrated Connector 1000 333. 3 66. 3 102. 3 500 166. 7 77. 7 113. 7 Pipe Connection 166. 7 W/m 2

3. Separate Connector Al Pipe Connection Welded Integrated Connector Nonintegrated connector (Al Pipe) Contact resistance between Pipe-Connector & Connector -Panel Shield Thermal Contact Scaled Thermal Gradient Conductance Contact Conductance (W/m 2 K) T min (K) T max (K) 50. 3 90. 1 2000 666. 7 58. 8 96. 4 1500 500. 0 61. 4 98. 4 1000 333. 3 66. 3 102. 3 500 166. 7 77. 7 113. 7 2000 666. 7 64. 6 101. 1 1500 500. 0 68. 7 104. 5 1000 333. 3 75. . 2 111. 3 500 166. 7 93. 1 130. 7 666. 7 W/m 2 166. 7 W/m 2

4. Separate Connector SS Pipe Thermal Contact Scaled Thermal Shield Thermal Gradient Conductance Contact Conductance T min (K) T max (K) (W/m 2 K) Welded 50. 3 90. 1 2000 666. 7 58. 8 96. 4 1500 500. 0 61. 4 98. 4 Integrated Connector 1000 333. 3 66. 3 102. 3 500 166. 7 77. 7 113. 7 2000 666. 7 64. 6 101. 1 1500 500. 0 68. 7 104. 5 Non-integrated connector (Al Pipe) 1000 333. 3 75. . 2 111. 3 500 166. 7 93. 1 130. 7 2000 666. 7 67. 8 105. 1 Non-integrated connector (SS Pipe) 500 166. 7 96. 2 137. 8 Pipe Connection 666. 7 W/m 2 Contact resistance between Pipe-Connector & Connector -Panel 666. 7 W/m 2

2. 50 E-05 Engineering Data – Thermal Expansion Coefficent of Thermal Expansion (K-1) 2. 00 E-05 1. 50 E-05 1. 00 E-05 Panels: Al 1100 5. 00 E-06 Cooling Tubes: Al 6061 T 6 Fixations: Ti 6 Al 4 V SS 316 0. 00 E+00 0 50 100 150 Temperature (K) 200 250 300

Cool Down Deformation Welded Shield

Cool Down Deformation Welded Shield

Cool Down SS Pipe

Cool Down SS Pipe