SSL

LAu Ceramlc ackage

ueslgn, llow, & SLaLus
!ason MchaLe & Cswald Slegmund
LAu Permeuc ackage CodparenL 8evlew
3 Aprll 2013
SSL
Ceramlc ackage ueslgn Cvervlew
use sLandard" sealed Lube
maLerlals and processlng
Ceramlc brazed body wlLh Cu
lndlum well
Slgnals and Pv passed Lhrough
Lhe anode on kovar plns
3mm Lhlck boroslllcaLe (Schou
833) wlndow
na
2
kSb blalkall phoLocaLhode
PoL seal (ln8l alloy)
x" shaped lnLernal supporL
sLrucLure
8.66" square, ~0.68" Lhlck
(lncludlng wlndow)
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 2
Mechanlcal 1esL unlL
SSL
lnLernal SLack-up
Large area requlres lnLernal
supporL sLrucLure Lo prevenL
wlndow/anode cracklng under
aLmospherlc pressure load
ueslre Lo supporL wlLhouL creaung
Lrapped spaces lead Lo x" shaped
supporL sLrucLures
Comblnauon of lnsulaung ceramlc
x-grlds and sLalnless x-shlms
x-grlds lsolaLe Pv poLenuals whlle
x-shlms faclllLaLe Pv dlsLrlbuuon
(and sLack helghL ad[usLmenL)
1op x-grld serves Lo reLaln enure
sLack durlng processlng
1oLal lnLernal sLack helghL ls .003"
Lo .006" !"#$% Lhe Lop of Lhe Cu
well - Lo ensure wlndow seal
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 3
Anode Cap x-grlds lnLer-MC x-grld
CaLhode Cap x-grld Mech. 1esL unlL
Pv lnLernal ulsLrlbuuon Lxample
8ouom Pv ConLacL
SSL
Ceramlc 8razed 8ody Assembly
All maLerlals refracLory or meLal
and proven for vacuum Lube
manufacLurlng
Plgh-Lemp meLalllzed ceramlc
anode wlLh kovar feedLhrough
plns
Ceramlc sldewall frame
lndlum seal well ls sLamped from
ClL copper (used for opumal
lndlum wemng and ducullLy)
Cnly Lwo braze [olnLs (save for Lhe
plns), uslng lnCuSll braze alloy
Large C1L mlsmaLch beLween Cu
and ceramlc, buL Lhe Cu ls very
ducule and does noL over-sLress
Lhe ceramlc
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 4
SSL
Ceramlc Anode
SubsLraLe ls .100" Lhlck 96
alumlna
Plgh-Lemp meLalllzauon
36 slgnal sLrlps lnslde
Solld ground plane ouLslde
Peaded kovar plns for slgnal and
Pv feedLhrough
Pv plns are double-ended Lo
dlsLrlbuLe Pv verucally wlLhln Lhe
Lube - one ln each corner
lns (76 ln LoLal) brazed lnLo
anode one of Lwo ways
CuSll braze prlor Lo body braze
(currenL preferred meLhod)
lnCuSll braze slmulLaneously wlLh
body braze
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 3
SSL
PlsLory of Lhe Ceramlc ackage 8razlng
SLarLed wlLh P
2
brazlng aL unlLed SuperLek (uSl)
lnlually CuSll alloy kovar Lo alumlna brazes, buL close buL noL
perfecL C1L maLch coupled wlLh kovar sLrengLh resulLed ln
cracked ceramlcs - 2 auempLs
1hen lnCuSll alloy brazes wlLh Cu lndlum well (currenL deslgn) -
1 auempL
noL gemng consLrucuve process feedback from uSl
SwlLched Lo vacuum brazlng aL Cmley lndusLrles
lnlually dld lnCuSll alloy brazes wlLh all ln one go (anode plns,
and body [olnLs) - 4 auempLs (all leaky aL plns)
SwlLched Lo Lwo sLep process. CuSll anode pln braze, Lhen
lnCuSll body braze - 3 auempLs (wlLh lmprovlng resulLs)
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 6
SSL
1wo-SLep 8razlng rocess
lns brazed lnLo anode rsL
CuSll braze alloy - ~830C process LemperaLure
SLresses are mlnlmal (plns are small) - Muluple re-braze runs posslble
MlugaLes rlsk aL Lhe lncurslon of lncreased expense
1hree consecuuve leak-ughL anode-pln assemblles slnce swlLchlng Lo Lhls
meLhod
8ody brazed uslng pre-plnned anode assembly
lnCuSll braze alloy - ~730C process Lemp, so no re-melL of pln braze CuSll
alloy
lmproved nal assemblles
rlor Lo uslng Lhe Lwo-sLep process, assemblles had gross leaks -
parucularly aL Lhe plns
1he Lwo sLage process lmmedlaLely resulLed ln assemblles LhaL were
much closer Lo leak ughL and lncremenLal progress has been made slnce
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 7
SSL
Ceneral 8raze CommenLs
nelLher braze vendor was pleased wlLh Lhe
meLalllzauon on Lhe anodes
Screenlng performed by CaL-l Class
lnconslsLenL Lhlckness (some qulLe Lhln areas) and poor
reglsLrauon
nelLher vendor parucularly llkes lnCuSll - poor
wemng characLerlsucs compared Lo CuSll (for
example)
Cmley has opLed Lo swlLch anode pln braze Lo alCuSll
uSl has opLed Lo swlLch anode pln braze Lo Cu/Au (braze
washers on order, should arrlve soon)
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 8
SSL
8ecenL 8raze AcuvlLy
Cmley auempLed alCuSll braze on lasL remalnlng anode
from rsL baLch
unsuccessful aer 4 braze runs
know meLalllzauon lssues wlLh Lhls anode, and leaks seem
Lo be where meLalllzauon was scavenged by alloy
llnal 7 sldewalls have been meLalllzed aL uSl and are
ready for braze use. 1hese were done wlLh Lhlcker
meLalllzauon Lhan Lhe rsL baLch.
LasL 6 anode subsLraLes are ln process
Laser machlnlng and nal machlnlng compleLe
MeLalllzauon ln progress aL uSl. Screenlng belng done aL uSl,
and uslng Lhlcker meLalllzauon on Lhese Loo.
LxpecLed dellvery 4-3 weeks
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 9
SSL
8e-8raze of 8razed 8ody Sn07
erformed 2x P
2
re-brazes aL uSl of Cmley 88A Sn07
used a slow Lhermal prole Lo mlnlmlze sLresses ln Lhe body durlng
reheaL
llrsL re-braze was a slmple reheaL wlLh clamplng pressure
Second re-braze added lnCuSll pasLe aL leak slghLs
Can perform muluple processes wlLhouL desLroylng bodles
CreaLly lmproved Lhe leak raLe
lnlual leak raLe was 10
-1
Lorr-l/s (dlsLrlbuLed over several lnches)
osL rsL re-braze now 210
-6
and 410
-8
leaks. Second re-braze
dldn'L change anyLhlng
now our rsL poLenual body for a seal Lube
8elnvlgoraLes Lhe P
2
brazlng program (wlLh caveaL)
8equlres dlrecL personal lnvolvemenL aL Lhe vendor (Lo ensure
approprlaLe auenuon Lo deLall)
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 10
SSL
8razlng luLure lans
P
2
braze one anode wlLh Cu/Au alloy aL uSl
lf lL's leak ughL, Lhen use lL ln a CuSll body braze
lf noL successful, conslder reLurnlng Lo Cmley
We plan Lo be conservauve wlLh our lasL 6 blLes aL
Lhls apple
Should geL more plece parLs ln Lhe plpellne once Lhe
fundlng slLuauon has seuled ouL?
n8: P
2
brazlng aL uSl ls abouL 40 Lhe cosL of
vacuum brazlng aL Cmley
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 11
SSL
8razed 8ody labrlcauon llow
Metallization
(4-5 weeks)
Laser cutting
(1-2 weeks)
Finish machining
(2-3 weeks)
Anode substrates
(4-5 weeks)
Kovar pins
(4-8 weeks)
Copper wells
(large stock)
Ceramic sidewalls
(6-7 weeks)
Metallization
(2-3 weeks)
InCuSil BODY
BRAZE
(<1 week)
CuSil ANODE
BRAZE
(<1 week)
Leak test
(1 day)
Leak test
(1 day)
VIABLE
BRAZE BODY
18 uecember 2012 LAu uCL ro[ecL 8evlew 12
SSL
88A 8ased uemounLable
Allows Lube-llke Lesung of MC and
oLher lnLernal componenLs ln
brazed body wlLh uP readouL
elecLronlcs prlor Lo Lube fabrlcauon
A good use for one of Lhe leaky all-
lnCuSll brazed bodles - Celvaseal
Lhe leaks
Cu lndlum well o-rlng seals Lo
mounung backplaLe
8ackplaLe mounLs Lo exlsung 8" xuL
demounLable deLecLor Lank
laLe epoxled Lo anode Lo mlnlmlze
vacuum bowlng and provlde a
mounung locauon for elecLronlcs
ueslgn near compleuon, golng Lo
fabrlcauon soon
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 13
SSL
near-1erm lans
labrlcaLe brazed bodles from plece parLs currenLly ln
process (slx assemblles maxlmum)
llnallze deslgn & fabrlcaLe Lhe 88A demounLable
ush 88A Sn07 Lhrough Lube processlng
8e-braze 88A Sn06 as backup Lo Sn07
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 14
SSL
8ACku SLluLS
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 13
SSL
8" 1ube rocess llow
Mount Sb and alkali
sources on FW ange
Functional test
MCP
scrubbing
Photocathode
shoot
QE check
(Hot)
Receive and
inspect 8.66" B33
window
Inspect, clean,
test body sub-
assy, Indium ll,
vacuum bakeout,
leak test
Wet clean and
plasma clean
Prepare tank
tooling for detector
body assy
Load getters,
X-Grids, MCPs,
and make HV
contacts
Check, test and
clean MCPs
Inspect & clean
internal parts
Vacuum
bakeout
Functional test
Functional test
Window seal
(Hot)
Functional test
(Cold)
TANK LOAD
Prepare electronic/
optical test station
Prepare QE test optics,
lters and std diodes
Up to Air
Scrub source, &
recording setup
RGA setup
Blue Processes
at Vacuum
Black Processes
at Air
Evaporate NiCr &
Cu border
Plasma clean
Prepare & clean
tank tooling for
8.66" windows
Prepare & clean
forming well ange
Detailed assembly ow in backup matl.
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 16
SSL
Ceramlc ackage LlecLronlcs
3 Aprll 2013 LAu Permeuc ackage CodparenL 8evlew 17
8eadouL elecLronlcs for Lhe ceramlc package provlded by u of
Pawall (varner Lalk on LlecLronlcs)
8ased on 8elle-ll l1C readouL elecLronlcs
18x 4-channel pre-ampller boards
9x 8-channel analog Lo dlglLal daughLer cards
1x lnLerface board and 1x power board
8eady for Lesung
need ceramlc package based demounLable deLecLor or Lube Lo LesL