Thermally Conductive, Carbon Foam Material for Constructing Silicon-Based Tracking Detectors

The next generation of silicon-based detectors for tracking charged-particles in high energy physics experiments will impose demanding requirements. One of these requirements involves the need for thermally efficient, low mass, dimensionally-stable support structures exposed to high radiation fields. This project will develop specially processed carbon foam for use in sandwich structures that support silicon-based detectors. The approach will be based on a thermally enhanced, very-low-density carbon foam material, ideally suited for transporting electronic heat to an embedded cooling tube in the structural sandwich member. In Phase I, test articles, with a 600 fold increase in thermal conductivity over virgin foam, were produced and tested. Cooling tests, with pre- and post- temperature cycling, demonstrated good results, and no failure of the foam was observed. In Phase II, the thermal resistance in high flux regions will be lowered by adding high conductivity fibers that are uniquely oriented to enhance joint thermal and structural properties. Performance enhancements will be evaluated using representative sandwich structures with the thermally enhanced foam cores. Extensive thermal cycling tests will be conducted to verify joint integrity.Commercial Applications and other Benefits as described by the awardee: The carbon foam should find use as a replacement for honeycomb core materials in physics detectors where lightweight thermally conductivity is needed. In addition, the carbon foam technology could have applicability to the core material for high temperature heat exchangers for military and commercial aircraft, replacing Inconel and Hastelloy X fins