THE NATIONAL INSTITUTE FOR NUCLEAR
PHYSICS AND HIGH ENERGY PHYSICS
LHCb Project Document No:
LHCb-2003-XXX
Institute Document No.
NIOT01-35246
Created: 24/11/2003
Page: 1 of 9
Modified: 26/04/2004
Rev. No: 4
(DRAFT)
SUPPLY OF GOLD-PLATED TUNGSTEN WIRE FOR THE
LHCb OUTER TRACKER DETECTOR MODULES
- Annex to Partial Order 35246 -
Abstract
The first part of this note defines the specific technical requirements of the sense wires for the LHCb Outer Tracker
detector modules. The sense wires are the anodes of the drift straw tubes. The base material of the wire is tungsten,
plated with 6% of gold.
The second part of this note defines the programme of work for the production of the sense wires, as agreed between
NIKHEF and California Fine Wire, 338 So. Fourth Street, Grover Beach, CA 93433-0199.
Prepared by:
Antonio Pellegrino, NIKHEF
antonio@nikhef.nl
Checked by:
Distribution List
Approved by:
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Rev. No.3 - (DRAFT)
History of Changes
Rev. No.
Date
Pages
Description of changes
1
25/11/2003
All
2
30/11/2003
All
Modified technical specification of gold-plating.
Added Part II – Statement of Work, with detailed description of
tentative production program schedule
3
03/12/2003
All
Updated section cross-references. Added 5 Km to 1st batch and
subtracted 5 Km to 3rd batch. Update section on quality control:
measurements every 5 spools
4
26/04/2004
Updated production schedule
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Rev. No.3 - (DRAFT)
Table of Contents
1
PART I – TECHNICAL SPECIFICATION....................................................................................................4
1.1
1.2
1.3
1.4
1.5
1.6
2
SCOPE .................................................................................................................................................................4
TECHNICAL DESCRIPTION...................................................................................................................................4
TECHNICAL SPECIFICATIONS ..............................................................................................................................4
CLEANLINESS .....................................................................................................................................................4
WIRE SPOOLING .................................................................................................................................................4
TESTING .............................................................................................................................................................5
1.6.1 Tests of Engineering and Electrical Properties .....................................................................................5
1.6.2 Test Reports and Traceability ...............................................................................................................5
PART II – STATEMENT OF WORK ............................................................................................................7
2.1
2.2
2.3
WIRE QUANTITIES AND BATCHES ......................................................................................................................7
PACKING AND TRANSPORT .................................................................................................................................7
PROVISIONAL ACCEPTANCE ...............................................................................................................................8
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1
1.1
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Rev. No.3 - (DRAFT)
Part I – Technical Specification
Scope
This document details the technical specifications of the Au-plated tungsten wire used as sense wires for the strawtubes of the LHCb Outer Tracker detector modules.
1.2
Technical Description
The wire selected as anode wire for the LHCb Outer Tracker is the same wire used for the Outer Tracker detector
of the HERA-B experiment at DESY, Hamburg. It was produced by California Fine Wire, 338 So. Fourth Street,
Grover Beach, CA 93433-0199, henceforth referred to as CFW.
The basic elements to which we will refer in this note are:
 The raw tungsten wire, henceforth referred to as “base wire”
 The Au-plated wire, henceforth referred to as “final wire”.
1.3
Technical Specifications
The wire must fulfill the following technical specifications:
1. Radius of the final wire: 0.001 (0.0254 mm) ±1.5% by weight.
2. Circularity tolerance (ovality) of the final wire: maximum 0.001 mm.
3. The base wire shall be plated with 5-7% Au by weight, per electro-deposition. The gold used will be soft
gold (mean knoop hardness between 70 and 110), with a percentage of impurities below 100 PPM.
4. The final Au-plated wire shall have a minimum tensile strength of 130 g and a minimum elongation of 1%.
5. The final Au-plated wire shall have good straightness (CFW straightness grade #1) with a maximum
average deviation of 50 mm from a straight line joining the wire ends of a 1000mm wire flat on a clean
glass. Specifically kinks, curls, twists etc. are not acceptable.
6. The base wire must be free of volume and surface defects, specifically cracks, splits, deep-scratches,
inclusions etc.
7. A light electrolytic cleaning must remove all traces of oxides and contaminants (e.g. graphite, lubricants,
etc.)
8. Any additional element deposited (e.g. nickel flashes, alloying elements) shall be clearly indicated by the
supplier.
9. The Au plating must be smooth, compact, of uniform thickness and free of defects: specifically, lack of
plating, poor adhesion, flaking, peeling, deep scratches, blisters, discoloration, inclusions etc. are not
acceptable.
10. The final Au-plated wire shall have an electrical resistance of approx. 110 Ohm/m at 25º Celsius.
1.4
Cleanliness
As the final wire shall be used in a gas detector, the cleanliness of the product is of extreme importance.
The final Au-plated wire shall have a clean surface finish and be free of any contaminant, e.g. oil, dirt, dust, fibres,
etc. The wire is intended to be used without further cleaning at the production sites. Any cleaning must be done
without affecting the quality of the wire. Handling of the finally cleaned wire must be done in clean conditions, in
particular using gloves.
1.5
Wire Spooling
The final wire will be spooled on CFW bakelite spools type “CFW 400”. Each spool shall contain 1,000 meters of
wire. Only one continuous length of wire shall be wound on each spool. Spooling shall be done with controlled
tension to give a uniform layer type winding: specifically no loose winding, stretching, and sticking is acceptable.
The wire must unreel readily and uniformly from the top to the bottom of the spool.
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1.6
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Rev. No.3 - (DRAFT)
Testing
The quality of the product and its compliance to the technical specification (see Sect.1.3) shall be tested by CFW at
the production facility. Test results shall be included in a test report (certification of compliance), which shall
contain:
 A unique test report ID
 An optical bar-code (see Sect.1.6.2)
 Test data
 Description of failure modes in each case
 Description of any conditioning performed
 Test-coupons, wherever appropriate.
1.6.1
Tests of Engineering and Electrical Properties
The following tests shall be carried out by CFW on wire samples at the beginning of each production run, every
five wire spools produced, and at the end of each production run, and
1. Physical test of tensile and yield strength.
2. Physical test of elongation.
3. Metallographic test of percentage of Au plating. The Au plating quality shall be controlled by visual,
microscopic examination and certified against defects.
4. Electrical test of wire resistance.
5. Chemical analysis of base-wire material.
NIKHEF reserves the right to request base- and final-wire production samples to be supplied for testing at
NIKHEF.
The delivered wire and wire samples will be tested at NIKHEF and provisional acceptance (see Sect.2.3) of the
wire shall be based on the results of the following tests:
1.
2.
3.
4.
5.
6.
Measurement of wire diameter
Microscopic and metallographic inspection of gold plating
Measurement of wire straightness
Measurement of tensile strength
Measurement of electrical conductivity
Inspection of cleanliness
The test results will be shared with the supplier and taken into account in production. In case of failed tests, the
supplier is notified and the affected batches are returned (see below about Provisional Acceptance).
1.6.2
Test Reports and Traceability
Production runs and each test report shall be clearly identified and traceability insured.
Each production batch shall be assigned a unique LOT ID.
To ensure traceability, each test report (certificate of compliance) shall be assigned a unique Test Report ID and,
additionally, each hardcopy of a test report shall bear an optical-bar code encoding the following information:
“W” – LOT ID – Test Report ID. Each test report shall be labeled by a label containing:
1. Optical-bar code: W–LOT ID–Test Report ID
2. Radius of the final wire
3. Date (of testing or manufacturing)
4. LOT ID
5. Test Report ID
6. Rating
7. % of Au plating
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Each packed wire spool shall also be clearly identified by an optical-bar code encoding “W” – LOT ID – Test
Report ID; the “Test Report ID” assigned to a wire spool shall be either the ID of the last test performed prior to
the production of the spool or the ID of the next test performed after the production of the spool. The complete
labeling of the wire spools is described in Sect.2.2, Packing and Transport.
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2.1
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Rev. No.3 - (DRAFT)
Part II – Statement of Work
Wire Quantities and Batches
The hardware considered a deliverable in this program, henceforth referred to in whole or in part as the “Supply”,
is a total length of 225 Km of the final Au-plated wire. The technical description of the wire is given in Part I of
this note. All test-coupons and –samples are also deliverable items.
The production program is divided into several phases. In Phase 1, the first batch of the final Au-plated wire shall
be produced to check the manufacturing process and expected performances of the wire, as described in Sect.1.3 of
Part I of this note, and the tests of the engineering, physical and electrical properties, as described in Sect.1.6 of
Part I of this note. After final acceptance by NIKHEF of this first batch as described in Sect.2.3, in Phases 2, 3, and
4 of the program, the remaining 100% of the supply will be delivered to NIKHEF.
The first batch shall be delivered before January 19th 2004. The schedule of the remaining production program shall
be agreed between NIKHEF and CFW after final acceptance of the first batch at NIKHEF. The production
schedule of each batch shall be confirmed by CFW within one week after receiving NIKHEF order. A tentative
production program is given in Table 1 below.
Activity
Duration:
Start Date:
Phase 1 (1)
Agreement on Technical specification and
Statement of Work
Completion Date:
01/12/2003
Delivery of first batch of 30 Km of final
wire to NIKHEF
7 weeks
01/12/2003
19/01/2004
Notification of Acceptance or Rejection of
first batch
2 weeks
19/01/2004
30/01/2004
Review of End-Item Tests
1 week
20/02/2004
1 week
27/02/2004
Review of Packaging,
Transportation
Shipping
and
Phase 2 (2)
70 Km of final wire delivered
6 weeks
26/04/2004
04/06/2004
Acceptance or Rejection at NIKHEF
2 weeks
07/06/2004
18/06/2004
Phase 3 (3)
60 Km of final wire delivered
6 weeks
27/09/2004
05/11/2004
Acceptance or Rejection at NIKHEF
2 weeks
08/11/2004
19/11/2004
Phase 4 (4)
65 Km of final wire delivered
6 weeks
24/01/2005
04/03/2005
Acceptance or Rejection at NIKHEF
2 weeks
07/03/2005
18/03/2005
Table 1 Tentative production schedule.
NIKHEF reserves the option to purchase additional wire at the same conditions during the course of 2004 and
2005.
2.2
Packing and Transport
Packing must ensure adequate protection against damage, loss of cleanliness, dust etc. during handling and
transport.
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Each wire spool shall be enclosed in a plastic bag to protect against dust: a dehumidifier bag is included; each
plastic bag with a wire spool shall be packed into a plastic box matching the spool dimensions such that no
movement of the spool within the plastic box is possible.
Boxes and method of delivery must ensure against damage during transport. In particular, movements of the wire
in the direction perpendicular to the spool winding direction caused by drop of the spool, bad handling etc. must be
prevented.
The different batches must be clearly identifiable; therefore each spool shall bear a label containing:
 Optical bar code, as in Sect.1.6
 Lot ID
 Test Report ID
 Tare
 Base material (tungsten) and Au-plating percentage
 Length of the spooled wire
 Production date
2.3
Provisional Acceptance
NIKHEF reserves the right to sample test each delivered batch in order to check that the characteristics and quality
of the supplied wire conforms to our Technical Specification: provisional acceptance will be granted within 4
(four) weeks of delivery. In case of non-conformance, NIKHEF will allow the supplier an additional 4 (four) weeks
to deliver an acceptable batch. If this batch is again non-conforming, NIKHEF reserves the right to cancel the order
without further notice and without any payment or compensation being due by NIKHEF with respect to such
cancellation. If defects are detected in the delivered wire during use, NIKHEF will return the defective container
for full replacement, free of charge.