LIMADOUHEPD-02 TRACKER
Cold plate prototypes production and preliminary test
Corrado Gargiulo
Massimo Angeletti
March 2020
Outline
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LIMADOU Stave mechanics Cold plate
o N. 6 Cold plate producedo CP1=HEPD02_D0_1
o CP2=HEPD02_D1_1
o CP3=HEPD02_D1_2 (cut to samples)
o CP4=HEPD02_D1_3
o CP5=HEPD02_D1_4 (cut to samples)
o CP6=HEPD02_D1_5
o Preliminary Test o On Cold plate
o Planarity (CP3, CP6) DONE
o Bending (CP1) DONE
o Modal (CP2) DONE
o Heat cycle (CP1) DONE
o CTE (CP1, CP2) DONE
o On Coldplate+ End Blocks
o Modal (CP2) (DONE)
o Heat cycle (CP2) (DONE)
o CTE (CP2) (DONE)
Layout
LIMADOU Mechanical Stave
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• Nomenclature:
196mm
Cold plate (CP)
Mechanical Stave (MS)
Silvia Coli
Silvia Coli
34.6mm
Layout• CFRP Materials and Glue
Coldplate CFRP: prepreg K13D2U
Glue Cold plate/End Blocks interface: Masterbond EP37-3FLFAO Technical Data Sheet (link)
Note: Glass fleece to be added at the interface with connectors to prevent galvanic corrosion, or anodize end-block (unsealed MIL A 8625 Type III). Not applied in the prototypes.
Note: Parylene coating can be considered for electrical insulation but it will sensibly lower the peel strength. Suggestion is to relay on the electrical isolation by colplate resin and the glue for chips. Specific test can be foreseen
Materials
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Carbon fleecek13D2U
Number of filaments per carbon thread 2000. FAW Fibre Areal Weight 120 g/m2. 33% resin content. Resin Cyanate ester EX1515.
Carbon Unidirectional Prepreg: R-EX1515/K1D2U 2K Carbon Fleece
Carbon fibre mats 8g/m2
Filaments[K=1000]
E1[GPa]
Xt /Xc
[MPa]E2
[GPa]Yt
[MPa]K
[W/mK]CTE
[10-6K-1]K13D2U [0] fibre 2K 935 3688 800 -1,1
E[GPa]
Xt
[GPa]HT fiber
240 4,4
Layout• Design 0:
#1 CP produced: CP2=HEPD02_D0_1
Cold Plate
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0.4 mm
2.0 mm
0°
Ply Material/sub-laminate
Thickness(mm)
Orientation(deg)
Number
Fleece 0.02 1
K13D2U_EX1515 0.120 90 1
K13D2U_EX1515 0.120 0 1
K13D2U_EX1515 0.120 90 1
Fleece 0.02 1
Total 0.4
• Flat part
Ply Material/sub-laminate
Thickness(mm)
Orientation(deg)
Number
Fleece 0.02 1
K13D2U_EX1515 0.120 16
Fleece 0.02 1
Total 2
• Lateral part
30.6 mm
34.6 mm
6.6 mm
Layout• Design 1:
Rib thickness from 2.0 to 1.9mm
CP width unchanged 34.6mm
#5 CP produced: CP2=HEPD02_D1_1
CP3=HEPD02_D1_2
CP4=HEPD02_D1_3
CP5=HEPD02_D1_4
CP6=HEPD02_D1_5
Cold Plate
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0°
90°
196mm
1.9 mm30.8 mm
34.6 mm0.4 mm
6.6 mm
Ply Material/sub-laminate
Thickness(mm)
Orientation(deg)
Number
Fleece 0.02 1
K13D2U_EX1515 0.120 90 1
K13D2U_EX1515 0.120 0 1
K13D2U_EX1515 0.120 90 1
Fleece 0.02 1
Total 0.4
• Flat part
Ply Material/sub-laminate
Thickness(mm)
Orientation(deg)
Number
Fleece 0.02 1
K13D2U_EX1515 0.120 15
Fleece 0.02 1
Total 1.9
• Lateral part
Test• Planarity test
Objective: CP flatness investigation
Test article: Cold plate (#3,#6)
Test procedure:
Equipment: Mitutoyo Crystal apex 7106,
QVP Camera (Optical probe)
Cold Plate #3, #6
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Planarity <0.100mm
Tolerance zone 0.082 mmUpper Tol. 0.038Lower Tol. -0.044
No. of pts. 84Min./Max. Pnt. 82/41Std. dev. *4 0.075Flatness 0.082
EP-DT Detector technologies
Tolerance zone 0.054 mmUpper Tol. 0.025Lower Tol. -0.029
No. of pts. 84Min./Max. Pnt. 77/1Std. dev. *4 0.087Flatness 0.054
PlaneTolerance ZoneMin/ Max Points
CP#6
CP#3
Test• 3 Point bending test:
Objective: Elastic properties
Test article: Cold plate (#)
Test procedure: tested up to 200gf
Linear behaviour; EIequivalent=9.37 106 Nmm2
Cold plate #1
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No plastic deformation observed (marble table) No visual damages have been detected (microscope)
• Bending test:Objective: Plastic behaviour
Test article: Cold plate (#1)
Test procedure: Gradually tested up to 780gf (Safety Margin x Load Factor x payload)
Distributed weight over a surface
(longitudinal and transversal)
EP-DT Detector technologies
0.00
0.01
0.02
0.03
0.04
0 25 50 75 100 125
Dis
pl.
[m
m]
Force [gf]
3points bending test
Before[mm]
Linear(Before[mm])
Test• Bending test before and after heat cycle:
Objective: Resistance to heat load
Test article: Cold plate (#1)
Test procedure: 1 cycle (65°C)
Planarity inspection before and after.
Tested up to 200gf (50 gr steps)
Cold plate #1
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No damages or plastic deformations have been detected Same mechanical properties before and after
0.000.010.020.030.040.050.060.070.080.09
0 100 200 300
Dis
pl.
[mm
]
Force [gf]
3points bending test
Before
After_1
After_2
EP-DT Detector technologies
0
10
20
30
40
50
60
70
0 10 20 30 40
[°C
]
[min]
Temperature-Time
10 min65 °C
25 °C
Test
Test set-up: CTE
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Set-up used to measure the Cold plate CTE and the strain at the interface Cold plate/End blocks
• CTE measurements set-up 1:
EN MME Mechanical Measurements Laboratory
• Cameras: Manta MG-505B• Resolution: 2452*2056 pixels• Lenses: Ricoh FL-CC5028-2M• Focal Length: 50 mm• Aperture: f8
• Field of View: ≈ 180*100 mm• Pixels per mm: ≈7• Facet size: 19 pixel ≈ 2.7 mm• Grid Spacing: 11 pixel (33% overlap)
Test procedure: performed in a laboratory furnace (heating rate 0.5 °C/min). • 3 temperature sensors attached to the back surface of the CP.• Digital image correlation system to observe the strain*. Equipment: • France Etuves XFL050 (laboratory furnace). • PT100 sensors. • DANTEC Q400 3D (digital image correlation system) configured according to the
following parameters:
(link)
*White pattern for visual recognition
Test
Test set-up: CTE
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Set-up used for to measure the CTE of specimens
• CTE measurements set-up 2:
EN MME Mechanical Measurements Laboratory
Dilatometer DIL 402 E
The transfer of current between the primary and the secondaries of the LVDT displacement transducer is controlled by the position of a magnetic core
An LVDT Displacement Transducer comprisesa primary (A) and two secondaries (B) coils
Test procedure: Cold plate specimens of side ribs and plate measured in the dilatometer while changing temperatureEquipment: Dilatometer DIL 402 E
Test• CTE measurement test (preliminary)
Objective: Evaluate CTE in X,Y directions
Test article: Cold plate (#2) only, no end-blocks
Test procedure: ramp 0.5 °C/min
Set-up: CTE Test setup 1
Cold plate #1, #2
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CTEs < 1.5 ppm·C-1 ; test at the setup limit*
Applying linear regression to the strain-temperature curve
CTE = 1.3 (CP #1) 0.9 (CP #2) ppm·C-1 in X Direction CTE = 0.6 (CP #1) 0.5 (CP #2) ppm·C-1 in Y Direction
EN MME Mechanical Measurements Laboratory
YX
*Test repeated in set-up 2
CP#1
CP#2
CP#1
CP#2
Test• CTE measurement test (preliminary)
Objective: Evaluate CTE in X,Y directions
Test article: n.6 Samples (#S#) from Cold plate (#3)
Test procedure: 70 °C, ramp 0.5 °C/min
Set-up: CTE Test setup 2
Specimens Cold Plate#3
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CP long <4 ppm·C-1 ; CP trans <2 ppm·C-1 ; CTE rib <3 ppm·C-1
Rib (longitudinal)
Cold plate (transversal)
Cold plate (longitudinal)
EN MME Mechanical Measurements Laboratory
(link)
From 30C to 80C From 80C to 20C
Ex. Test behavior (rib S2)
Test• Strain
Objective: determine the thermally induced strains in the surface of the colplate due to differential expansion of both materials
Test article: Cold plate +End blocks
• Test procedure: ramp 0.5 C/min. Use of only one temperature sensor per specimen bonded with kaptontape to the back face of the aluminum connectors
Set-up: CTE Test setup 1
Cold plate #1; Cold plate #2
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1000-5000 micron/m @ 60 °C,
Araldite 2011 (used only for comparison)
Test results
Masterbond EP37-3FLFAO
The asymmetry observed between both sides of the colplates could be due to contact conduction
between the supporting structures and the connectors of the colplate. It is agreed to perform an
additional measurement over colplate 2 with special attention to avoid conduction between the
connectors and the supporting structures, and allowing a better view on the rib of the specimen.
(link)
EN MME Mechanical Measurements Laboratory
σ = 200MPa x 5/1000 = 1MPa; 4.8MPa tensile lap shear; 20 MPa tensile
Test• Heat Cycle test
Objective: Resistance to heat load cycles
Test article: Cold plate (#1) +Araldite2011 + End Blocks
Test procedure: 3 cycles (80, 100, 120 °C), (5 °C/min)
Between cycles, evaluation of:
- End-blocks/Cold plate interface (microscope), - planarity inspection on marble table.
Cold plate #1
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No interface damages have been detected.
0
20
40
60
80
100
120
140
0 20 40 60 80 100 120 140
[°C
]
[min]
10 min
120 °C
100 °C
80 °C
25 °C
Right side
Aft 120 °C
25 °C
before after
EP-DT Detector technologies
Test
Test set-up: Vibration
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• Experimental modal analysis set-up:
VISATON FRS8
Test procedure: sweep scan through multiple points pre-defined on the surface of the analyzed object. Input power spectral density coming from excitation source: loudspeaker or shaker.Equipment: • 3D Scanning Vibrometry System (PSV-500-3D), • loudspeaker (VISATON FRS8, with a linear frequency response up to 20000 Hz), • Shaker (MB Dynamics 50A modal exciter). The shaker can produce up to 225 N
peak force (when cooled with forced air) between DC and 4000 Hz. The shaker A solid-state power amplifier (MB Dynamics SL500VCF) with a frequency range between DC and 200Hz drove the exciter.
PSV-500-3D Scanning Vibrometer
MB Dynamics 50A modal exciter
Two different Excitation sources:
EN MME Mechanical Measurements Laboratory
Test• Modal analysis (Free-Free)
Objective: Evaluate natural frequencies
Test article: Cold plate (#2) only, Free-Free cond.
Test procedure: simply supported CP on foam excited by loudspeaker
Equipment: PSV-500-3D Scanning Vibrometer,
Excitation source: loudspeaker VISATON FRS8
Cold plate #2
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1st Mode 1522 Hz; 2nd Mode 1746 Hz; 3rd Mode 2358 Hz
1st Mode 1522 Hz 2nd Mode 1746 Hz
EN MME Mechanical Measurements Laboratory
Test setup
Scanning vibrometer Loudspeaker
foam
foam
3rd Mode 2358 Hz
Test resultsClick for movie
Test
Cold plate #2
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First freq. bending in longitudinal direction: 1522 Hz (no end blocks); second freq. bending transversal direction (1746 Hz)
• Modal analysis (Free-Free )(link)
EN MME Mechanical Measurements Laboratory
Test• Modal analysis (Fixed-Fixed )
Objective: Evaluate natural frequencies CP+EB
Test article: Cold plate (#2)+ EB., Fixed-Fixed.
Test procedure: XX
Equipment: PSV-500-3D Scanning Vibrometer,
Excitation source: Shaker MB Dynamics 50A
Cold plate #2
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Test setup
1st mode 803 Hz
2nd mode 1038 Hz
Fixed Fixed Shaker
EN MME Mechanical Measurements Laboratory
3rd mode 1534 Hz
Click for movie
4th mode 2201 Hz
Test
Cold plate #2
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• Modal analysis (Fixed-Fixed )
EN MME Mechanical Measurements Laboratory
Analysis• Modal analysis:
Material, mesh and boundary conditions (BC):
• Shell elements.
• Mesh size 1mm
• Same stack-up Design 1
Finite element analysis:
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Fixed-Fixed: Areas corresponding to End-blocks gluing have been fixed
A
A
A Ux, Uy, Uz =0
Materials:
Material/sub-laminate Thickness (mm) Or.(deg) Number
FGS-003 0.04 1
EX-1515/K13D2U 2K 0.107 90 1
EX-1515/K13D2U 2K 0.107 0 1
EX-1515/K13D2U 2K 0.107 90 1
FGS-003 0.04 1
Total 0.4
EX-1515/K13D2U 2K, 120gsm, 33% RC6
Lamina Properties (Koller & Springer)
E11 367.68 GPa
E22 6.35 GPa
E33 6.35 GPa
G12 5.76 GPa
G23 2.06 GPa
G13 2.06
v12 0.286
v23 0.538
v13 0.286
FGS-003
Lamina Properties
E 8.97 GPa
G 3.2 GPa
v 0.4 GPa
Material/sub-laminate Thickness (mm) Or.(deg) Number
FGS-003 0.0975 1
EX-1515/K13D2U 2K 0.107 0 15
FGS-003 0.0975 1
Total 1.9
Analysis• Free-Free: Results
Finite element analysis: modal analysis
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Tuning of the FE Model to match Modal test results on free free configuration
228Hz 1541Hz 1699Hz
1709Hz 2179Hz 2376Hz
1522Hz*
1746Hz 2358Hz*
*Experimental**Effective mass ratio (%)
Analysis• Fixed-Fixed: Results
Finite element analysis: modal analysis
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The modal shapes and frequencies are compatible with the test
1486Hz 2042Hz 2070Hz
2446Hz 2675Hz 2705Hz
1534Hz*
*Experimental
2567Hz*
2201Hz*
Y-Dir 32.1% *
**Effective mass ratio (%)
X-Dir 32.6% * X,Y,Z-Dir ~ 0% *
Y-Dir 31.5% * X- Dir 33.5% *Y-Dir ~ 7.44% *
(most in the ribs)(most in the ribs)
X-Rot 19.1% *
X-Rot 18.8% *
Y-Rot 27.8% *
Y-Rot 28.7% *
Z-Rot 41.2% *
Z-Rot 24.5% *
Back up
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BACKUP
Back up
Finite element analysis: modal analysis
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• Fixed-Fixed: mass contribution
Back up
Finite element analysis: modal analysis
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• Fixed-Fixed: mass contribution (extended)
Back up
Masterbond glue for end blocks gluing
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Back up
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