Accelerated testing of soft soldered, small-diameter, thin-walled CuNi pipes subjected to cyclic internal pressure loading

Small-diameter, thin-walled pipes have applications in a wide range of industries including high-energy physics, heat transfer, nuclear, medical and communications. However, there are currently no standards that exist for permanently joining these components either via welding (melting the base material) or soldering. As such it is difficult to determine the likely performance of a thin-walled pipe connection. Porosity is largely inevitable in soldered joints and is a determining factor in the performance of a connection. This study focused on characterisation of failure initiation and propagation within soft soldered CuNi thin-walled pipe joints under cyclic internal pressure loading. A step-stress accelerated life testing regime (SSALT) was developed to simulate the loads the joints would experience over their operational lifetime, in a shorter timescale. 10 soldered joints were studied in total, with varying levels of porosity within the soldered joints prior to testing. Pressurised Nitrogen gas was used to internally pressurise the samples, with cyclic loading between atmospheric conditions and a prescribed maximum pressure value. The results of the SSALT showed that the soldered samples experienced early failure through crack initiation and propagation through the solder. Cracks, or failures, were seen to initiate from existing voids, or porosity, within the soft-soldered joints. From this work, it can be concluded that the performance of soft-soldered joints under cyclic, internal pressure loading is strongly influenced by the presence of voids that are created during the manufacture of such soldered connections

Manufacturing technologies and joining methods of metallic thin-walled pipes for use in high pressure cooling systems

Small diameter thin-walled pipes, typically with a diameter less than 20 mm and a ratio of outer diameter to wall thickness is 20 or above, have increasingly become a key value adding factor for a number of industries including medical applications, electronics and chemical industries. In high-energy physics experiments, thin-walled pipes are needed in tracking detector cooling systems where the mass of all components needs to be minimised for physics measurement reasons. The pipework must reliably withstand the cooling fluid operation pressures (of up to 100 bar), but must also be able to be reliably and easily joined within the cooling system. Suitable standard and/or commercial solutions combining the needed low mass and reliable high-pressure operation are poorly available. The following review of literature compares the various techniques that exist for the manufacture and joining of thin-walled pipes, both well-established techniques and novel methods which have potential to increase the use of thin-walled pipes within industrial cooling systems. Gaps in knowledge have been identified, along with further research directions. Operational challenges and key considerations which have to be identified when designing a system which uses thin-walled pipes are also discussed

Mechanical and Microstructural Characterisation of Cooling Pipes for the Compact Muon Solenoid Experiment at CERN

The Compact Muon Solenoid (CMS) is a particle physics experiment situated on the Large Hadron Collider (LHC) at CERN, Switzerland. The CMS upgrade (planned for 2025) involves installing a new advanced sensor system within the CMS tracker, the centre of the detector closest to the particle collisions. The increased heat load associated with these sensors has required the design of an enhanced cooling system that exploits the latent heat of 40 bar CO2. In order to minimise interaction with the incident radiation and improve the detector performance, the cooling pipes within this system need to be thin-walled (~100 μm) and strong enough to withstand these pressures. The purpose of this paper is to analyse the microstructure and mechanical properties of thin-walled cooling pipes currently in use in existing detectors to assess their potential for the tracker upgrade. In total, 22 different pipes were examined, which were composed of CuNi, SS316L, and Ti and were coated with Ni, Cu, and Au. The samples were characterised using computer tomography for 3D structural assessment, focused ion beam ring-core milling for microscale residual stress analysis, optical profilometry for surface roughness, optical microscopy for grain size analysis, and energy dispersive X-ray spectroscopy for elemental analysis. Overall, this examination demonstrated that the Ni- and Cu-coated SS316L tubing was optimal due to a combination of low residual stress (20 MPa axial and 5 MPa hoop absolute), low coating roughness (0.4 μm Ra), minimal elemental diffusion, and a small void fraction (1.4%). This result offers a crucial starting point for the ongoing thin-walled pipe selection, development, and pipe-joining research required for the CMS tracker upgrade, as well as the widespread use of CO2 cooling systems in general

Precision measurement of the structure of the CMS inner tracking system using nuclear interactions

The structure of the CMS inner tracking system has been studied using nuclear interactions of hadrons striking its material. Data from proton-proton collisions at a center-of-mass energy of 13 TeV recorded in 2015 at the LHC are used to reconstruct millions of secondary vertices from these nuclear interactions. Precise positions of the beam pipe and the inner tracking system elements, such as the pixel detector support tube, and barrel pixel detector inner shield and support rails, are determined using these vertices. These measurements are important for detector simulations, detector upgrades, and to identify any changes in the positions of inactive elements

Precision measurement of the structure of the CMS inner tracking system using nuclear interactions

The structure of the CMS inner tracking system has been studied using nuclear interactions of hadrons striking its material. Data from proton-proton collisions at a center-of-mass energy of 13 TeV recorded in 2015 at the LHC are used to reconstruct millions of secondary vertices from these nuclear interactions. Precise positions of the beam pipe and the inner tracking system elements, such as the pixel detector support tube, and barrel pixel detector inner shield and support rails, are determined using these vertices. These measurements are important for detector simulations, detector upgrades, and to identify any changes in the positions of inactive elements

Strategies and performance of the CMS silicon tracker alignment during LHC Run 2

The strategies for and the performance of the CMS silicon tracking system alignment during the 2015–2018 data-taking period of the LHC are described. The alignment procedures during and after data taking are explained. Alignment scenarios are also derived for use in the simulation of the detector response. Systematic effects, related to intrinsic symmetries of the alignment task or to external constraints, are discussed and illustrated for different scenarios