LEB 30 VII 09C. Garion

Aluminum bellows for experiments

C. Garion & R. Veness, TE/VSC

LEB 30 VII 09

Outline

• Development history

• 2 ways of procurement Japanese company CERN

• Development at CERN Material Bellows parameters Bellows manufacturing Present situation and further actions

• Conlusions

C. Garion

LEB 30 VII 09C. Garion

Development History• Formed Bellows

– European industry R&D project (1999-2001)• Thick-walled aluminium bellows are

made for cryogenic applications, but no standard production of thin-walled bellows in Europe

• 2 development projects were followed with European manufacturers, but neither successful results nor much interest

• Machined Bellows– CERN Workshops (2001-2006)

• Good results obtained for 0.3 mm thick bellows

• Pieces installed in LHCb (small stroke)• Leaks during production and test linked

to material form and quality

R.Veness LEB 30 VII 09

LEB 30 VII 09C. Garion

Japanese Industry• Background

– Both Titanium and Aluminium bellows have been used in accelerator vacuum systems in Japan (TRISTAN and J-PARC)

– They were produced by Japanese industry in large numbers following joint development projects with the labs

– With help from KEK, a potential supplier was identified, and CERN issued a specification

R.Veness

LEB 30 VII 09C. Garion

Development Contract• Prototype series

– Order placed in June ‘09 for a series of 3 bellows, as per the drawing opposite

– Delivery expected end Oct ’09

• Full series– An offer has been made for a

series of 30 bellows– Unit Price ~ 1800 CHF/piece– 3 months delivery

R.Veness

LEB 30 VII 09C. Garion

CERN development for formed bellows Material

Requirements:

Formability (high ductility)

Weldability (also with 2219)

Low Heat affected zone

Available in thin foils

Good mechanical properties

2 materials: series 5000 (Magnesium):

Well weldable

Good corrosion resistance

Mechanical properties acceptable

Non heat treatable

5754 H22:

0.3mm thick

5083 H111, 0.2 and 0.3mm thick (available beginning of September)

0.2 and 0.3 mm thick

LEB 30 VII 09C. Garion

DesignAlgorithm of optimization of bellows expansion joints

(Based on EJMA)

•Minimise the objective function:

•inequality constraints: bellows convoluted lengthinner diameterouter diameterbellows maxi compression

membrane stressmembrane stress membrane & bending stress

fatigue life

column buckling in-plane squirm

c

p3

pmT

fblax n

n

w

tdE

C)x(F

0LL blmax 0DD minin

0DD outmax 0minbl

0SS 1ad 0SS 2ad

0)SS(S 4334

0N)S(N 0ftf

0PP 1col 0PP 2inp

Atlas constraints (technical specification EDMS 429891):

Lbmax = 100 mm

Dmin ~ 60 mm

Dmax = 80 mm

Stroke = -24/+8mm

Nf > 500 cycles

LEB 30 VII 09C. Garion

DesignBellows parameters

Thickness 0.3 mm Thickness 0.2 mm

Other wish: if possible use the same tooling:

0.3mm thick: 13 convolutions, bellows length: ~96mm, Inner diameter: 60 mm, outer diameter: 78.8mm

0.2mm thick: 8 convolutions, bellows length: ~59mm, Inner diameter: 60 mm, outer diameter: 78.8mm

Design has to be compatible with formability capacity

LEB 30 VII 09C. Garion

Bellows manufacturing(courtesy of L. Prever Loiri, EN/MME)

Aluminum foil Rolled tube & longitudinal weld (EB) Welds of the end fittings (EB)

Forming @150°C combining pressure and displacement loading

Cut of the end fittings

LEB 30 VII 09C. Garion

Present situation2 materials have been chosen:

•5754 has been received, metallurgical and mechanical tests have been done (EN/MME)

•5083 has been ordered. Delivery is expected beginning of September

Bellows parameters have been defined and optimized

Welding procedure has been determined

Metallurgical observations (grain size, inclusions) Tensile test at room temperature

Micrograph of longitudinal weld

LEB 30 VII 09C. Garion

Present situationTooling (forming and welding) have been designed and manufactured (EN/MME)

First tube equipped with the end fittings is ready for forming

Tubes are equipped with the end fittings

Analysis is being done to optimize the forming process (pressure-displacement function)

LEB 30 VII 09C. Garion

Forming simulation

Plastic strain after forming

Mesh Deformed shapesMesh

Pressure

Displacement

Further detailed FE analysis will be done (A. Sarrio Martinez)

LEB 30 VII 09C. Garion

Next steps

Forming tests on 5754 tube:

-As assembled

-After heat treatment (annealing)?

Qualification tests:

-Leak tightness

-Fatigue life a room temperature

-Stability?

Reception of 5083 and metallurgical tests

Welding tests

Forming

Qualification:

-Leak tightness

-Fatigue life a room temperature

-Stability?

LEB 30 VII 09C. Garion

Tentative schedule(Alba Sarrio)

Task Name Duration Start

Order material (Al-5083) 16 wks Mon 5/18/09

Crack propagation test 50 days Thu 5/28/09

Define test 2 mons Thu 5/28/09

Calibration of the test 2 wks Thu 7/23/09

Characterize material Al-5083 2 mons Mon 9/7/09

Tooling for the forming and welding 2 wks Thu 5/28/09

Circular weld and edges 112 days Thu 6/11/09

Al-5754 6 wks Thu 6/11/09

Al-5083 2 wks Mon 11/2/09

Forming 110 days Mon 7/6/09

Numerical simulations 3 wks Mon 7/6/09

Al-5754 6 wks Thu 7/23/09

Al-5083 3 wks Mon 11/16/09

Qualification tests 123 days Wed 7/15/09

Testing tooling production 1 mon Wed 7/15/09

Prototype test 1 mon Mon 12/7/09

Series production 3 mons Mon 1/4/10

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr

First bellows by August 2009

End of prototyping: 12/09

Series

LEB 30 VII 09C. Garion

Conclusions

An order has been placed to a Japanese company for aluminum bellows prototypes

Development of aluminum bellows at CERN is well advanced:

-2 Material chosen: 1 delivered and 1 available beginning of September

-Forming process at “high” temperature will be used

-Bellows parameters are defined

-Welding process are defined

-Tooling for forming are ready

Forming process will probably not be straight forward. Iterations might be necessary.