Specification for Brazing.pdf

CONSTRUCTION PRINT

JUNE 13, 2013

ADVANCED PHOTON SOURCE

A R G O N N E N A T I O N A L L A B O R A T O R Y Doc. No. 410201-00122-02

Rev.

Approved

PDH

Date 2/29/12

Title: Technical Specification for Gold Brazing of GlidCop, Stainless Steel and Copper for Beamline Vacuum Devices Page ii of iii

*The document number as it appears on this page only shall be used to identify this document. The last two digits denote the revision number of this document (see Revision Authorization block below).

This document is fully representative of the Document No. only when the revision number on its pages correspond with those in the index below.

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REVISION AUTHORIZATION

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030923-02 040210-

120229-02

DATE 12/3/03 02/10/04 02/29/12

APPROVED

BY

PDH _ 4 5 1 PDH

ANL-242 (3-83)

Approved

PDH

Date 2/29/12

Stainless Steel and Copper for Beamline Vacuum Devices Page iii of iii

TABLE OF CONTENTS

INDEX OF PAGE REVISIONS ............................................................................................................................. ii

1.0 SCOPE

1.1 Purpose

1.2 Required Equipment

2.0 APPLICABLE DOCUMENTS AND /OR SPECIFICATIONS

2.1 Application

2.2 Recommended Practices and Standards

3.0 TECHNICAL REQUIREMENTS

3.1 General Requirements

3.2 Machining Requirements

3.3 Cleaning and Surface Treatment

3.4 Brazing

4.0 QUALITY ASSURANCE AND TEST REQUIREMENTS

4.1 Certification

4.2 Calibration and Control of Instruments

4.3 Acceptance Testing at Vendors Facility

4.4 Test at Argonne

5.0 PREPARATION FOR DELIVERY

Approved

PDH

Date 2/29/12

Stainless Steel and Copper for Beamline Vacuum Devices Page 1 of 5

1.0 SCOPE

1.1 Purpose

The purpose of this specification is to define the APS Engineering Support Division’s gold and silver brazing procedure for joining GlidCop, stainless steel and copper in the fabrication of beamline vacuum devices.

1.2 Required Equipment

A brazing furnace with either a vacuum or hydrogen reducing atmosphere capable of operating over the range of 800 to 1200° C is required.

2.0 APPLICABLE DOCUMENTS AND /OR SPECIFICATIONS

2.1 Application

2.1.1 Deviations. The documents listed in paragraph 2.2 of the exact issue shown form a part of this standard to the extent specified herein. Any deviations from these documents or their requirements shall be requested by the contractor and approved by the Laboratory prior to any contractor action being taken. Requests for Deviations shall be made on a Supplier Disposition Request (ANL-311).

2.1.2 Conflicts. Any conflicts between the requirements of this Technical Specification and those of any applicable document shall be brought to the attention of the Laboratory' s Subcontract Administrator prior to any related action on the part of the contractor.

2.1.3 Exceptions. Where the materials or standards to be employed in the manufacture of any part are not identified in this Technical Specification or the documents referenced herein, the contractor shall submit for the Laboratory's approval the materials or standards he proposes to use.

2.1.4 Referenced Documents. Documents, which are referenced without citation of section or paragraph, shall apply in their entirety. Where there is a citation of section or paragraph, only that cited portion is applicable.

2.2 Recommended Practices and Standards

ANL Technical Specification 410201-00095, Vacuum Requirements of Ultra High Vacuum Devices for Beamlines.

3.0 TECHNICAL REQUIREMENTS

3.1 General Requirements

3.1.1 Absolute cleanliness of all components is required. No dust, dirt or grime shall be permitted, no cleaning residue shall be permitted, and no hydrocarbon contamination shall be permitted.

Approved

PDH

Date 2/29/12

Stainless Steel and Copper for Beamline Vacuum Devices Page 2 of 5

3.1.2 Nitrogen used in the cleaning processes and tasks described in this specification shall be at least 99.99% pure, nitrogen preferably from an evaporated LN2 source. High purity (99.99%) water pumped nitrogen bottled gas may also be used. Nitrogen compressed by a water-lubricated (or non-lubricated) compressor is referred to as water pumped. Oil pumped nitrogen is strictly prohibited.

3.2 Machining Requirements

3.2.1 No silicone or sulfur-based cutting fluids shall be used. The recommended cutting fluid is Trim Sol.

3.2.2 No operation causing contaminants to be embedded into chamber surfaces shall be permitted.

Grinding with resin-bonded wheels, rouge, emery cloth, crocus cloth or similar abrasives is prohibited.

3.3 Cleaning and Surface Treatment

3.3.1 General Requirements. Our UHV requirements are for low outgassing rates on the order of 4×10-12 Tor•liter/sec•cm2 and no detectable hydrocarbon contamination.

3.3.2 Recommended Cleaning Methods.

3.3.2.1 Clean parts to be brazed in 2% Citranox de-ionized water solution at elevated temperature (45° C) with ultrasonic agitation and sufficient mechanical agitation to produce good fluid flow over all the surfaces for 5 minutes.

3.3.2.2 Final rinse in de-ionized water heated to approximately 35° C.

3.3.2.3 Blow dry with nitrogen heated to 40° C.

3.3.2.4 Any deviation from above methods must first be approved by APS XFD personnel.

3.3.3 Storage. Use cleaned parts within 24 hrs or store in a vacuum desiccator.

3.4 Brazing

3.4.1 Assembly Area. Components shall be assembled in a clean, oil-free, low humidity (air conditioned) area that is compatible with the requirements of section 3.1.1.

3.4.2 Gloves. Lint-free nylon or latex gloves are to be worn during assembly. No fingerprints are permitted.

3.4.3 Cleaning. Prior to brazing the parts shall be cleaned in accordance with Section 3.3 of this specification.

3.4.4 Pre-Assembly Inspection. Prior to assembly, all component faying surfaces shall be visually inspected. Surface shall be clean, have the required surface finish, and be free from nicks, Approved

PDH

Date 2/29/12

Stainless Steel and Copper for Beamline Vacuum Devices Page 3 of 5 cuts, dents, burrs, or defects that would prevent filler from flowing into the joint or preventing correct assembly.

3.4.5 Filler Material. The braze filler material shall be high vacuum quality gold/copper or silver/copper foil and/or paste. The filler material must be pre-approved by ANL prior to brazing.

3.4.6 Clamping. The components shall be held in the appropriate positions during the brazing operation by the use of weights or suitable clamps such as wedges. Fixtures should be designed such that thermal expansion does not cause them to loosen.

3.4.7 Braze Cycle. The items shall be furnace brazed in a reducing atmosphere of ultra-high purity hydrogen. To ensure proper knowledge and control of the temperature of the part being brazed, several thermocouples, at least three, should be attached to the part in addition to the thermocouples monitoring the furnace temperature. A braze cycle is dependent on the characteristics of the furnace being used and the exact part being brazed and thus must be customized to the furnace and part.

The braze procedure should include control of atmosphere, furnace ramp and cooling rates, and pre-braze hold time and hold temperature, all of which are part size dependent. If multiple braze cycles are necessary to complete an assembly, the highest temperature cycle should go first with the subsequent cycle at a lower temperature than the first. No more than two braze cycles for the same component shall be permitted.

The actual part temperature must slightly exceed the liquidus temperature of the filler material to assure full melting and flow of the filler material across the entire joint (that is to account for thermal gradients). The time at brazing temperature should likewise be minimized to just that required for a good braze while limiting the diffusion of the gold or silver into GlidCop or other base material.

3.4.8 Visual Inspection. Visual inspection of all braze joints shall be done after brazing wherever joints are accessible. Clear evidence of brazing filler metal flow and bonding shall be present at the joint edges.

4.0 QUALITY ASSURANCE AND TEST REQUIREMENTS

The following examination requirements and those requirements specified in the Technical Specification or on the drawing for the particular device shall comprise the minimum acceptable for the UHV device.

4.1 Certification

All certification of materials, hardware, processes, calibrations and test data shall be signed by a contractor representative authorized to sign such certifications.

4.2 Calibration and Control of Instruments

Approved

PDH

Date 2/29/12

Stainless Steel and Copper for Beamline Vacuum Devices Page 4 of 5

Accuracy of instrumentation used during tests shall be verified by the contractor by means of periodic calibration traceable to the National Institute of Standards and Technology. The Laboratory shall be given timely notice of any calibration discrepancies or problems. Calibration records shall be available to the Laboratory's personnel.

4.3 Acceptance Testing at Vendors Facility

The acceptance testing shall be performed in accordance with the ANL approved contractor's test plan, and the results submitted to the Laboratory for approval. The following items are the minimum requirements for inclusion in the acceptance tests.

4.3.1 Vacuum Braze Joints. All vacuum braze joints are to be verified leak tight by vacuum leak testing. The test procedures shall comply with ANL Technical Specification 410201-00095.

4.3.2 Water Braze Joints. All water braze joints are to be verified leak tight by water pressure testing to 225 psi unless another pressure level is stated on the applicable drawing. Only clean de-ionized water shall be used. After the test is complete, the water passages shall be blown dry with dry nitrogen.

4.3.3 Ultrasonic Tests. If required on the applicable drawing, the braze joints shall be ultrasonically tested. Unless otherwise stated on the drawing, no detectable voids are permitted in the braze area that will be remaining after final machining.

4.3.4 Witness Tests. Argonne APS staff reserves the right to witness these tests at the vendor's site.

4.3.5 Test Results. Certified test results are to be shipped with each item. The test results are to be identified by the appropriate purchase order number, assembly number and a sequential identity or serial number as discussed in Section 5.1 of this Specification.

4.4 Test at Argonne

Leak tests will occur at Argonne with all data compared to that supplied by the vendor. Any components not meeting the above requirements will be rejected and returned to the vendor. Vendor nonconformances require the completion of an ANL-626, Nonconformance Report, which are to be entered into the Issues Management Tracking System (IMTS).

5.0 PREPARATION FOR DELIVERY

5.1 Each assembly shipped shall be identified by the appropriate purchase order number, assembly number and a sequential identity or serial number.

5.2 Any moving components on an assembly must be firmly secured for shipment in a manner that precludes damage from motion and vibration.

Approved

PDH

Date 2/29/12

Stainless Steel and Copper for Beamline Vacuum Devices Page 5 of 5

5.3 Assemblies must be secured for shipment in fashion that protects the assembly from dust, dirt and weather or water damage. The assemblies must be securely fastened, padded, boxed and/or crated for shipment in a suitable manner for prevention of shipment damage to any assembly and its weather/dust protection and insure their safe delivery to the Laboratory.