1. 1. pg 1 N ew ! 3D C A D in teraction & M ovies Product Development for A-Tube Supply ChainSupply Chain Overview &Overview & OutcomeOutcome Key LearningKey Learningss Feasibility is goodFeasibility is good manufacturabilitymanufacturability needs workneeds work SEE: Supply Chain communication matrix & link immediately to key business partners and their company info. Cert. of complianceCert. of compliance Quality AssuranceQuality Assurance paper work andpaper work and specsspecs
2. 2. pg 2 Table of Contents Technical Glass Altair TechnologyLarson Glass Garland Precision Agilent Lower Level Material Material Transformation & Assembly Integration SANDT Applied Physics 11 20 23 5 Thin Film Tech
3. 3. pg 3 Introduction LP1 (Lab Proto #1) Retrospective Purpose: System Requirements: Navigation: Audience: This is a multi-purpose document and meant to be read at different levels of details based on the audience. COMMUNICATE There have been a lot of queries regarding the status of this project and the lab units. Hopefully this will answer those as well as detail out the key learning's, progress and next steps in development. CENTRALIZE This is also intended as a starting point for production documentation. This pulls together a lot of separate documents & details across the entire supply chain. COODINATE A lot of effort has been made to facilitate communication between Agilent and the vendors. Moving forward, these efforts need to increase as we turn over deliverables to manufacturing, the supply chain changes, and improvements are implemented. This is a broad base distribution. All participants are requested to give feed back either within the adobe editor or off-line to myself. DEVELOPMENT ENGINEERS This document is an archive of development and learning across all the LP units. May this serve as a central point of reference as resources change. MANAGMENT Management changes throughout the organization require that they come up to speed on the project at different levels. This will serve as both a status updates and business impact capture. SUPPLY CHAIN PARTNERS All S.C. members are under NDA (non-disclosure agreements) and though this is primarily an Agilent documentation, I want to include them for feedback and coordinated efforts moving forward. The document is designed to be able to navigate to the desired information and level of detail required for the reader with ease. PDF ONLY Read and / or Print as a PDF only Bookmarks click the bookmarks icon to navigate by root tree external to the document Links There are a lot of links within the text and pictures to direct the reader to associated or detailed information. Comments click the comment icon to read inserted comments of others or the reader toolbar icon to inset comments of your own. You should be prompted to free upgrade to the appropriate web site for the application you are attempting to use. For full use of this document I recommend Flash 8.0, Adobe reader 8.1, Microsoft media and/or real player and associated graphic card to support these.
4. 4. pg 4 Executive Summery Supplier Part Process Learning's Improvements Tech Glass Chemical prep Toluene by itself devitrifies on the glass Use 3 chem. in order: Toluene, Acetone, IPA Thin Film QA data Need to acquire along with the parts Crystal Vogel mount Mechanical design more robust than preliminary tests revealed Work with vendor to collect data and improve design. Adding Getter to LP2 & LP5 Adding vented ceramic to LP2 & LP5 Bending pins to mate header induced unnecessary strain difficult to Spot welding with the legs interference Design is rated to withstand only 75PSIG Production HV process will only subject the part to 45PSIG Need to call out flared end . 1.75" call out of straight wall of glass > 0.1". Larger diameter glass will be used on production protos Will flare edge to minimize ovality & increase weld / reworkabiliy Welding Lost Vacuum integrity at 100C at weld point Moving this process to within Tech Glass Anode machinist issues on 2 rounds of 5 sets Adjusted material thickness and outsourced to another supplier Cu Pipe will change to 3/8 dia to increase manufacurability Late delivery set expectations on the front end across broader audience Increase communication and OF involvement to drive deadlines. Header assembly Add alignment specification to print Header assembly Add additional leak check points to discern of failure is process or material. Old Mini Task pump was insufficient for process replaced with new unit & added gate valve Data transfer from NT 4.0 painful Migrated RGA software to IRP computer Move process to Tech glass Qualify with LP5 created fixture to assist in electrical interface PS limit was 165kV Increased to 192kV by eliminating the V limit Need to add ON/OFF power cycle need to purchase 2 cameras that were removed for customer support Added Magnification fixture Need to validate SW /Gui test need to purchase and install x,y motors and controllers Final Test could not measure spot size indirectly with Genesis camera's Agilent Tech Bake Out High voltage seasoning KG-400-T-SPCL Larson Altair Tech Mounting cage New Mount part will have 2 legs (not 4) and receiving holes are aligned to correct distances FTSP-6 (6 pin header) AP Tech Vacuum integrity Click Icon (left) to go to KEY Learning's LP! UNIT Performance Functionality Requirement SPECIFICATION P/F Gun Gun Power perform at 10k hrs Variance 5months from PO release awaiting for balance of order. 1 instance of non-conforming gun from AP. Returned with others for repair. Overall supplier Quality is good. Still gaining ground on learning the product & process. More tooling and design improvements will be implemented on PP1-4 units
5. 11. pg 11 LP1 Supply Chain Technical Glass Altair TechnologyLarson Glass W / Monel / Cu Target Threaded SS Gun sleeve Thin Film Technologies Garland Precision Precision machined OFHC base Agilent Lower Level Material Material Transformation & Assembly Integration Processing, Integration, & Test Agilent LVLD W Plasma sputter deposition FTSP-6 BAKE HV season Integrate Final Test SANDT System Applied Physics Electron Gun Assembly KG-400-T-SPCL SST components for gun assembly ImprovingAt RISK GOOD Supplier Status Pass Pass Pass / lost vacuum Fail/skip N/A Move mouse over & click part, supplier, & process for details Braze & TIG weld QA test, integrate, weld, align, assemble N7280- 67900 X-ay Tube
6. 12. pg 12 Supplier Communication Matrix Supplier WEB Address Contact Position E-mail Phone Technical Glass, Inc. www.techglass.com 15400 E. Batavia Dr. Aurora, CO 80011 Ron Bihler Owner, Senior Eng rbihler@techglass.com (303)367-8619 Carol Peters Purchasing Agent cpeters@techglass.com (303)367-8619 Larson Electronic Glass www.larsonelectronicgl ass.com 2840 Bay Road Redwood City, CA 94063 Chuck Kraft Senior Eng gls2mtl@att.net 650-369-6734 Altair Technologies, Inc. http://www.Altair USA.com 980 Hamilton Avenue Menlo Park, Ca, 94025 Jerry Walias Sales JerryW@altairusa.com (650) 508-8700 x 121 Chris Ferrari Engineer cferrari@altairusa.com (650) 508-8700 x 123 Curtis Allen President CurtisA@altairusa.com (650) 508-8700 x110 Applied Physics Technologies http://www.a-p- tech.com/ 1600 NE Miller Street McMinnville, Oregon 97128 USA Cory Fast Engineer Cfast@A-P-Tech.com (503) 434-5550 x207 Florcia Hamilton Purchasing Agent FHamilton@A-P-Tech.com (503) 434-5550 Kevin Kagarice Research Scientist KKagarice@A-P-Tech.com (503) 434-5550 William A. Mackie, Ph.D Owner BMackie@A-P-Tech.com (503) 434-5550 Thin Film Technologies Inc http://www.thinfilm technology.com/h 153 Industrial Way Buellton, CA 93427 Tom Ives President tives@thinfilmtechnology.com (805) 688-4949 Bob Stokes Quality manager bstokes@thinfilmtechnology.com (805) 688-4949 Garland Precision machining N.A. 4000 Cordelia Ln Soquel, CA 95073 Glen Garland Owner garland@cruzio.com (831) 462-1314 SANDT http://www.sandt.com .cn/english/e- p008.htm No 188, Yanghebang Rd, Songjiang High Tech Park Shanghai, China Jerry Tang President jtang@aerosino.com +86 21 3763 3098 Joyce Lao Supply chain mng +1 949 351 0588 Joyce Lao Sales agent +1 949 351 0588 Jerry Tang Engineering jtang@aerosino.com +86 21 373 3098 Jerry Tang RnD eng liaison jtang@aerosino.com +86 139 173 11806 Yifang Wei Production Mng +86 21 3763 3088 Hanyun Cai Regulatory agent +86 21 3763 3088 x1201 Agilent Technologies Inc http://www.Agilent .com 900 S taft rd loveland Colorado 80537 USA Bee Giak OF Planner bee-gaik_koay@Aglilent.com +6 04 680 2809 Erick Lewark RnD eng Erick_lewark@agilent.com +1 970 679-2975 Eric Miller RnD eng Eric_Miller@Agilet.com +1 970 679 3805 Agilent Technologies Microwave (Malaysia) Sdn Bhd (463532-M) Building 5 Bayan Lepas Free Industrial Zone,Penang,11900, LIM,KOK- SUNG Regulatory agent kok-sung_lim@agilent.com +60 4 680-7105 shanmugam Rajamany Production Mng shanmugam_rajamany@agilent. com +6 04 8197804 RETURN link
7. 13. pg 13 Materials & Design Pin # Scheme Outer pins are odd# Inner pins are even # 2 outer short leads are 5&6 2 inner short leads are 1&3 Lead Lengths (in) pin # outer inner 1 0.500 0.000 2 1.125 3.500 3 0.500 0.000 4 1.125 3.500 5 0.500 3.500 6 1.125 3.500 Filament Gnd Filament (+) Getter (+) Focus V (+) Mechanical mount KG-400-T-SPCL --- LP1 PN KG-400-TF-SPCL new PN (3) (8250 glass composition) Mechanical mount Performance FTSP- 6 Production PN (7052 glass composition) Cross Section of Design improvement A B C There were 3 areas of design margin increase. 1 Overall length of header to increase dielectric stand-off capability. This was reduced as an effect of A (above) 2 Pin spacing increased to maximize mechanical strength along with straight Kovar pins 3 Future PP units will use a flared Kovar welding lip to maintain circularity and ease of weld and re-work. There were 3 areas of design margin to be addressed and one critical failure. A I did not call out a spec for the flare diameter. This was adjusted at Tech Glass but should be noted on the print to be >1.75 . B There was some indicator of stress line in the header. This piece is rated to only withstand 75PSI force, which is the sum difference of the vacuum + external SF6. C- The glass OD reduces at a critical failure point. Subsequent LP units have a spec of >.1 future designs will leverage larger glass. Failure Point Vacuum loss occurred at the Kovar pinglass interface. Future builds will have more rigorous leak check of this to identify if the failure is related to assembly or material 1 1After Before 2 3 Pin-6 Getter not incorporated in LP1 Click link to see QA specs
8. 14. pg 14 Photo of HfC provided by: www.hbci.com/~wenonah/new/cryst als.htm LP units utilize a 4 leg design. PP units will improve with a integrated 2 leg design (shown) Design & Build LP1 unit utilized a non- vent Ceramic. Other LP units will use improved design (shown) Click in box to activate 3D model. See tool bar to activate explode & rendered views Enables slide bar controller to explode assembly Show model tree & views for additional control of parts RETURN link
9. 15. pg 15 The chart to the right is a composite from 12 units Q.A. test data from AP. A 2.5 or 95% CI (confidence interval) was established for each temperature range test set. These limits then set the SPC boundaries for expected outputs. Gun 20473 test data is shown as a green triangle and is within acceptable limits. It did require much greater power & temperature the expected During Final Test. Annealing Temp (1) limit and Current run-away Are displayed as limits for K & W r e s p e c t i v e l y . . Pretest Performance Post Analysis T vs W 7.70 8.41 9.01 7.12 6.59 1700 1800 1900 2000 2100 2200 2300 2400 2500 6 7 8 9 10 11 12 13 14 Power (W) Temp(K) means QA test data (12 guns) LP1 test data 95% CI LL 95% CI UL LP1 performance Lineofsight check Drop test directions X Click link to see QA test data. Four guns returned from HWE were extracted and repaired with new crystals and a vented Vogel mount at Applied Physics. These were then tested for both t h e r m a l & e m i s s i o n characterization at specific t e m p e r a t u r e s ( s e e performance data below). LP1 (labproto-1) unit was built with gun serial # 20473. Gun Test fixture at A-P Tech. The gun was re-tested at A g i l e n t d u r i n g H e a d e r a s s e m b ly f o r F i l a ment continuity (12 + 5 Ohms) and dielectric stand-off capability. See Material & QA (quality assurance) tracking p.30 for more details. At present, production standardized testing and equipment are b e i n g e x p l o r e d . Annealing Temp U.C.L Currentrun-awayU.C.L. (1) Journal of Materials Engineering and Performance Volume 3(2) April 1994 2 Major concerns were investigated in autopsy: mechanical durability & degradation of performance due to contaminants in tube. It was suspected that gun o p e r a t e d a b o v e t h e annealing temperature of the b a s e m a t e r i a l w i l l compromise the strength of the Vogel mount assembly. S o a d r o p t e s t w a s performed along 2 axis repeatedly at heights up to 8. The alignment was checked visually after each test. No perceptible shifts in alignment could be detected. There was some corrosion present across the Carbon and crystal back surfaces but there was no evidence of any Oxidization, proving the vacuum integrity was good. Future guns will be checked with an optical pyrometer prior to Final Testing on s u b s e q u e n t L P u n i t s .
10. 16. pg 16 Outlook Item Anode assembly Target assembly Process & Integrate Machined Cu, Monel, SST Purchased 1.33 CFF Chemical Clean (Cu target ultrasonic in IPA only) Click link to see QA test data. Hydrogen Fire CuSil (35/65) Braze TIG weld to glass assembly Machined W & Monel Provided Cu coated target Vacuum Fire Nicusil Braze WMonel Cusiltin Braze Cu Monel Leak Check (E-10 pp torr) Visual Inspect N7280-28034 Coated Cu Target provided by Thin Film Technologies Anode assembly Target assembly Machined Tungsten (W) & Monel OFHC 0.5 pipe, SST base, and 1.33CFF Part received and staged July 23rd. (click e-mail) Click over selected comments below to see feedback and details.
11. 17. pg 17 T h e m a c h i n i s t destroyed 1st set of material. 2nd set delivered had a surface defect. Not critical to quality (CTQ) but does not a d h e r e t o t h e surface call out on the print. . Performance & Delivery Future material will be provided by an alternate supplier. Units allocated for pp6-9, machined by Devenus in MY, have been built to print using a thicker wall and 3/8 OFCH pipe. . D i s t a n c e f r o m Corona guard O.D. to Glass I.D. is CTQ for dielectric s t a n d - o f f r e q u i r e m e n t s . Concentricity of parts and TRI (total indicated run-out) are the contributing factors. LP1 exhibited breakdown at the point during HV seasoning indicated above. Future iterations will call out < 0.1 TIR and increase the glass O.D. by 0.25. . M i n i m u m g l a s s strain is critical for vacuum integrity. This is visually inspected with a Polariscope. Strain is induced by either forced fits or non- t e m p e r a t u r e controlled welds . . LP1 exhibited very low stress by the lack of heavy gradient lines. Future iterations will be designed with a flared Kovar to minimize these factors. LP1 exhibited a leak at the weld joint during bake- Out process. It was sealed with HV torr seal which a l l o w e d i t t o p r o c e e d b u t reduced the upper limit temp to 375 C as a result. LP1 used a 45 degree cut on the pipe which is more susceptible to strain. Future LP units use a 1 bend radius as shown on LP3. . LP1LP3 Material delivery from Altair has been the leading factor is schedule slip. The major d e l a y s a p p e a r t o b e associated to working with lower level vendors, quality issues, and damage of parts at both machinist and within Altair. The scope of the assembly, the value added of Altair, and the material requirements have been reduced to negate these factors in the future. . LP1 LP3 LP4,5 LP2
12. 18. pg 18 Subsidiary of Williams Advanced Materials Air Side Vacuum Side Electron beam Vacuum Side Air Side Monel Tungsten (W) Copper (Cu) OFCH grade (Oxygen Free High Conductivity large crystal >99.99% purity) Target PerformancePre-Test Design Materials Heat generated from the E- beam (16W) is imparted into a region 0.1". Larger diameter glass will be used on production protos Will flare edge to minimize ovality & increase weld / reworkabiliy Welding Lost Vacuum integrity at 100C at weld point Moving this process to within Tech Glass Anode machinist issues on 2 rounds of 5 sets Adjusted material thickness and outsourced to another supplier Cu Pipe will change to 3/8 dia to increase manufacurability Late delivery set expectations on the front end across broader audience Increase communication and OF involvement to drive deadlines. Header assembly Add alignment specification to print Header assembly Add additional leak check points to discern of failure is process or material. Old Mini Task pump was insufficient for process replaced with new unit & added gate valve Data transfer from NT 4.0 painful Migrated RGA software to IRP computer Move process to Tech glass Qualify with LP5 created fixture to assist in electrical interface PS limit was 165kV Increased to 192kV by eliminating the V limit Need to add ON/OFF power cycle need to purchase 2 cameras that were removed for customer support Added Magnification fixture Need to validate SW /Gui test need to purchase and install x,y motors and controllers Final Test could not measure spot size indirectly with Genesis camera's Agilent Tech Bake Out High voltage seasoning KG-400-T-SPCL Larson Altair Tech Mounting cage New Mount part will have 2 legs (not 4) and receiving holes are aligned to correct distances FTSP-6 (6 pin header) AP Tech Vacuum integrity RETURN link