GLAST LAT Project March 24 2003 GLAST Large

GLAST LAT Project March 24, 2003 GLAST Large Area Telescope: Gamma-ray Large Area Space Telescope Tracker Subsystem WBS 4. 1. 4 6 D: Composite Panel Fabrication Thomas Borden Stanford Linear Accelerator Center Tracker Subsystem Engineer tborden@slac. stanford. edu 6 D Tracker Peer Review, WBS 4. 1. 4 1

GLAST LAT Project March 24, 2003 Agenda • • Facilities Tray Description and Types Manufacturing Flow Plan Tooling Quality Assurance Trays Production and EM Results Conclusions 6 D Tracker Peer Review, WBS 4. 1. 4 2

GLAST LAT Project March 24, 2003 Facilities • Plyform Sp. A, Varolo Pombia; Prime Contractor to INFN for Tray Fabrication and Assembly, – Subcontractor for closeout machining – Subcontractor for insert machining • INFN Pisa; ESPI Test of bare panels – Holographic test – System can detect de-lamination defects in face sheets, between face sheet and honeycomb and between face sheets and closeouts • Centrotecnica, Milan; Tray vibration testing of panels with bias circuits and Carbontungsten Fiber Wall – Qualification levels – Verification of fundamental frequency – Workmanship 6 D Tracker Peer Review, WBS 4. 1. 4 3

GLAST LAT Project March 24, 2003 Tracker Mid Tray 6 D Tracker Peer Review, WBS 4. 1. 4 4

GLAST LAT Project March 24, 2003 Tray Types Tray Type Face sheet Plies Tungsten Converter MID 1 lb/ft 3 4 3% Xo LIGHT 1 lb/ft 3 4 NO HEAVY 3 lb/ft 3 6 18% Xo TOP 1 lb/ft 3 4 3% Xo BOTTOM 6 D Honeycomb Core 3 lb/ft 3 6 NO Tracker Peer Review, WBS 4. 1. 4 5

GLAST LAT Project March 24, 2003 Manufacturing Plan Machine Closeouts (outside Vendor) Production Flow Diagram Incoming Material receiving Inspection ref I. L. 02 -105 Dimensional Verification of Closeouts Face Sheet Lay-up ref I. L. 02 -106 Install Inserts ref I. L. 02 -117 & I. L. 02 -118 Assembly of Face Sheet with Honeycomb with Redux 312 UL Dimensional Verification of inserts Assembly of Face Sheet/Honeycomb and Closeouts ref I. L. 02 -118 6 D Tracker Peer Review, WBS 4. 1. 4 Dimensional Verification and ESPI Testing (workmanship) 6

GLAST LAT Project March 24, 2003 Manufacturing Plan Production Flow Diagram Cont. Final Trimming and Cleaning Ref I. L. 02 -116 Final Dimensional Verification, weighing and QA Assembly of Bias Circuits to Panel Ref I. L. 02 -118 Workmanship Vibration Testing at Centrotechnica Assembly of Tungsten to Panel Ref I. L. 02 -118 Ship to INFN Ref I. L. 02 -119 All assembly processes per LAT-PS-01584 6 D Tracker Peer Review, WBS 4. 1. 4 7

GLAST LAT Project March 24, 2003 Tooling • All assembly tooling documented and released • All assembly tooling, and procedures, “proof tested” with EM hardware • Additional copies of “standard” tray tooling in production • Sufficient tools available to support production rate of 10 standard, 4 thick, one top and one bottom tray(s) a week 6 D Tracker Peer Review, WBS 4. 1. 4 8

GLAST LAT Project March 24, 2003 Tooling Tray assembly bottom plate Tray assembly top plate 6 D Tracker Peer Review, WBS 4. 1. 4 9

GLAST LAT Project March 24, 2003 Tooling Closeout bars 6 D Tracker Peer Review, WBS 4. 1. 4 10

GLAST LAT Project March 24, 2003 Tooling Closeout Insert Assembly Tool 6 D Tracker Peer Review, WBS 4. 1. 4 11

GLAST LAT Project March 24, 2003 Quality Assurance • All processes controlled by ISO approved procedures at Plyform (I. L. 02 -111, I. L. 02 -112, I. L. 02 -113) • Regular INFN-Pisa oversight at Plyform • Data Base Developed • Nonconformance Reporting – Plyform nonconformance reporting system per I. L. 02– LAT-PS-01584 specifies the following major Nonconformance reporting limits require halting production: • Rejection during dimensional inspection of more than 4 of the trays produced out of a continuous sample of 40 trays. • Rejection during dynamical tests of more than 4 of the trays produced out of a continuous sample of 40 trays. • Accidents resulting in irreparable physical damage (serious enough for tray rejection) to more than 2 of the trays produced out of a continuous series of 40 trays. 6 D Tracker Peer Review, WBS 4. 1. 4 12

GLAST LAT Project March 24, 2003 Data Base Main form: • select tray type • access all tray data Tray data sheet: • assembly data • bare panel measurements • final tray measurements (TBD) • subcomponents IDs and data • click on buttons to access details Luca Latronico – INFN Pisa 6 D Tracker Peer Review, WBS 4. 1. 4 13

GLAST LAT Project March 24, 2003 Data Base continued Bare panel dimensions (after clicking on dimensions button): • plots measurements of reference points along tray structure • plots sides BD/AC • flatness, orthogonality, parallelism seen by moving slide bar 6 D Luca Latronico – INFN Pisa` Tracker Peer Review, WBS 4. 1. 4 14

GLAST LAT Project March 24, 2003 Data Base continued Each submask containing detail measurements data and has a clickable legend for reference – MCM legend shown here for example Luca Latronico – INFN Pisa 6 D Tracker Peer Review, WBS 4. 1. 4 15

GLAST LAT Project March 24, 2003 Data Base continued Connected to Ladders DB – this mask tracks ladders IDs, location and currents (preencapsulation and postencapsulation) as measured at G&A/Mipot. Location/names given according to LAT-TD-00376 convention, e. g. : F – Front Side B - Back Side 0 - connected to FE 0 side …. 3 – connected to FE 23 side Luca Latronico – INFN Pisa 6 D Tracker Peer Review, WBS 4. 1. 4 16

GLAST LAT Project March 24, 2003 GLAST: Gamma Ray Large Area Telescope Trays Production & E. M. Results R. Bagagli INFN - sez. Pisa 6 D Tracker Peer Review, WBS 4. 1. 4 17

GLAST LAT Project March 24, 2003 E. M. Tray Production Tray name honeycomb Tungsten Top 4 plies 1 lb/ft 3 3%Xo Mid 4 plies 1 lb/ft 3 3%Xo Light 4 plies 1 lb/ft 3 // Heavy 6 plies 3 lb/ft 3 18%Xo Bottom 6 plies 3 lb/ft 3 // Defective 6 D Face sheet 4 plies 1 lb/ft 3 // Tracker Peer Review, WBS 4. 1. 4 18

GLAST LAT Project March 24, 2003 E. M. Results: ASSEMBLING IMPROVEMENTS 1) Dimensional Check procedure on the tool: - measure the tool in six points with a caliber - fill a form to compare the reference values with the measured values - If measured values are otuside ± 0. 03 mm, then the operator has to adjust the lateral wall and to check again the value 6 D Tracker Peer Review, WBS 4. 1. 4 19

GLAST LAT Project March 24, 2003 E. M. Results: ASSEMBLING IMPROVEMENTS Glue-line on the sandwich with dispenser on the bonding area (to avoid no-bonding area) Vacuum bag at standard temperature (to avoid air inclusion) -The glue fills all the bonding area - The exceeding quantity goes out and will be removed in Refining Step 6 D Tracker Peer Review, WBS 4. 1. 4 20

GLAST LAT Project March 24, 2003 Tray assembly tools tool In house Under construction total assembly tool 3 4 7 Tungsten tool 2 1 3 Kapton tool 1 1 2 Trimming tool 1 0 1 Tungsten assembly tool Tray assembly rate capability: 3 trays/day Upper plate Reference wall Trimming tool Lower plate 6 D Skin Tray Tracker Peer Review, WBS 4. 1. 4 Kapton assembly tool 21

GLAST LAT Project March 24, 2003 E. M. Results: DIMENSIONS 6 D Tracker Peer Review, WBS 4. 1. 4 22

GLAST LAT Project March 24, 2003 E. M. Results: FLATNESS 6 D Tracker Peer Review, WBS 4. 1. 4 23

GLAST LAT Project March 24, 2003 E. M. Results: ORTHOGONALITY & PARALLELISM 6 D Tracker Peer Review, WBS 4. 1. 4 24

GLAST LAT Project March 24, 2003 E. M. Results: TRAY DATABASE 6 D Tracker Peer Review, WBS 4. 1. 4 25

GLAST LAT Project March 24, 2003 Tests 6 D Tracker Peer Review, WBS 4. 1. 4 26

GLAST LAT Project March 24, 2003 Bare Panel: N. D. I. Test 6 D Tracker Peer Review, WBS 4. 1. 4 27

GLAST LAT Project March 24, 2003 Bare Panel: N. D. I. Test ESPI: Thermal Loads very effective to detect bare panel defects Skin-closeout debonding Honeycomb crash Honeycomb – Skin debonding 6 D Tracker Peer Review, WBS 4. 1. 4 28

GLAST LAT Project March 24, 2003 TG 07: Bare Panel + W + Bias Plane ESPI: Vibration TEST 817 Hz first resonance mode 1860 Hz second resonance mode 6 D Tracker Peer Review, WBS 4. 1. 4 29

GLAST LAT Project March 24, 2003 Conclusions • • All documentation in place. Database in place. Production Readiness Review scheduled for April 15, 2003. All tray materials needed are delivered or on order and will be available before need date. • Tray production will begin on May 1, 2003 6 D Tracker Peer Review, WBS 4. 1. 4 30