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US Stave Core Production. D. Lynn (BNL), LBNL Mechanical Meeting, Sep 2012. US Stave Fabrication Sequence. Differs mostly from UK sequence in that we pre-machine foam and make foam-pipe assembly Do we need identical standardized assembly of stave core in production?. UK Foam Split.

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slide1

US Stave Core Production

D. Lynn (BNL), LBNL Mechanical Meeting, Sep 2012

slide2

US Stave Fabrication Sequence

  • Differs mostly from UK sequence in that we pre-machine foam and make foam-pipe assembly
  • Do we need identical standardized assembly of stave core in production?

UK Foam Split

US Foam Split

slide3

Assembly Sequence and Institutions for US Stave Cores Built Up to Now

  • LBNL fabricates facings (either standard or co-cured). Ships to BNL
  • BNL glues CF tubes, foam-pipe assembly, honeycomb to first facing, and end closeouts . Ships to Yale
  • Yale grinds honeycomb. Ships to BNL
  • BNL glues last facing
  • Characterization (or QA) at BNL
  • Expect facings will continue to be fabricated at LBNL
  • All of the other steps could in principle be done at any of these institutions
  • E.g. at present we do grinding at Yale as they have access to own grinder, but at BNL our central machine shops can do it (for prototyping, they are way too expensive!)
  • Is it possible to skip grinding in future? (or perhaps use corrugated core??)
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Old Gantt Chart (2009) for Stave Core Assembly—I have not updated it

  • Chart implied ~ 3 weeks assembly and QA (not including facing fabrication).
  • Expect to maintain a throughput of 1/day (although maybe could do 2/day without much additional effort?).
  • Seems likely need at most two main centers of production (US and UK).
  • Where in US to make stave cores will require a comprehensive look at where hybrids, modules, stave cores, and final module mounting and stave testing will be done to maximize utilization of resources within US community – also will depend upon funding.
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