Plans for Stave Prototyping in Birmingham

Stave prototyping plans in Birmingham involve the development of innovative processes for co-curing, reducing the need for secondary bonding steps. Various materials and techniques are used to create high-quality staves for different applications.

• Prototyping
• Birmingham
• Stave
• Co-curing
• Manufacturing

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Uploaded on Mar 04, 2025 | 0 Views

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1. WP1 F2F @ Birmingham Plans for Stave Prototyping (Tim Jones) 15thMarch 24

2. SVT Stave Concept Alice Silicon Sensor Kapton FPC 0.1 mm Thick 0.1 mm carbon fibre Continuous fibre along central spine Allcomp K9 RVC Carbon Foam 3% Relative Density Ultem end interface w/ O-ring seal Duocel Aluminium Foam 8% Relative Density Ladder Prototyping 2 04/03/2025

3. Full-length Laminate Geometry Laminate Pre-preg: Lay-up: Cure: K13C2U (ATLAS stock) 45gsm 40%RC CPT ~ 0.045mm, density ~ 1.6g/cc [0/90] 0 along length 120 C / 6bar for 2 hours Ladder Prototyping 3 04/03/2025

4. Co-curing Really would like to develop a process that included (as much) co- curing as possible Co-curing reduces need for secondary adhesive bonding steps Secondary bonding of foam structures can lead to excessive glue up-take (porous). Solution in ATLAS ITk Endcap pixels is to use carbon veil impregnated with adhesive Good experience within ATLAS ITk Pixels with co-curing 3-ply [0/90/0] K13C2U/EX-1515 laminates Uniform coverage of foam no discontinuities Processing issues Foam crushing (6 bar pressure) solved by using spacers / custom cast silicone rubber in-fill blocks Appearance Symmetric laminate doesn t curl up Minimal print-through of foam structure on opposite surface of CFRP Ladder Prototyping 4 04/03/2025

5. Bond half-thickness co-cures ? Tool (not shown) supports pre-preg (cut to shape) Half-height foam sections placed on pre-preg Infill pieces inserted between foam pieces as required Co-cure & remove (hopefully!) in-fill pieces & extract co-cured laminate Bond top/bottoms together with adhesive impregnated carbo veil ala ATLAS Pixels. Ladder Prototyping 5 04/03/2025

6. Programme Develop manufacturing process What are the steps? What moulds / in-fill blocks are needed ? Design & manufacture master mould Small prototype could use 3D printing If time allows machine full-length medium density epoxy tooling board Manufacture carbon-mould from tooling Normally use HX42 (AmberTool ) tooling pre-preg - 60 C cure Manufacture Co-cures Manufacture foam blocks & position using in-fill pieces Dimensionality of first prototype would not be well controlled if using silicone / tooling-board in-fills lower CTE material for production parts Lay-up pre-preg, add foams and in-fill blocks & cure in carbon mould. Ladder Prototyping 6 04/03/2025

7. Status & Schedule AML busy with (paid for) ATLAS work ITK Pixel global supports / half-ring co-cures Likely to be a pause in ATLAS work in April before production half-ring co-curing starts in May (probably 3 days / week when running smoothly) In the mean-time we will Ladder Prototyping 7 04/03/2025