Case Study · EIC Program

LFHCal Calorimeter Absorber Structures

Forward Hadronic Calorimeter · Electron-Ion Collider · Brookhaven National Laboratory

Altrusion assembled a best-in-class U.S. manufacturing team to fabricate a 24.838-inch proof-of-concept absorber module including a demonstration of electron beam welding capability. The prototype, delivered to Brookhaven, validated fixturing, dimensional control, and post-weld shrinkage below predicted values; our production proposal is in evaluation. Demonstrated takt time establishes a clear production path to 6 complete modules per day.

24.838 in
Sample Assembly Length
Half-module · Pre-proposal build
6 / day
Module Takt Rate
Demonstrated · Scalable with fixtures
< Predicted
Post-Weld Shrinkage
EBW dimensional control validated
645
Full Contract Scope
8M modules · 52-week delivery

6-Phase Manufacturing Process

1
Material Procurement & Qualification
AISI 1020 carbon steel from Nucor Steel, Auburn NY · CMTRs per ASTM A830 · Magnetic permeability per ASTM A773
2
Precision Machining & Fabrication
9 component types on Mazak Palletech FMS · In-machine touch probing · Laser-engraved EBW weld path scribe lines
3
Pre-Weld Assembly & Jigging
Dedicated precision-ground spacer plates · Gap and alignment verification · Minimizes stacked tolerance buildup
4
Electron Beam Welding
NADCAP Merit · 52 years EBW experience · AWS D1.1 inspection · Secondary source qualified
5
Post-Weld Inspection & CMM
5-axis CMM · 10 ballooned GD&T characteristics per ASME Y14.5 · 59-channel go/no-go gap gauging · Formal inspection report per assembly
6
Electroless Nickel Plating & Packaging
ASTM B733 · 0.001–0.002 in thickness · Post-plate dimensional reverification · ISPM-15 crating

Prototype Photos

LFHCal absorber plates component viewLFHCal assembled module top viewLFHCal electron beam weld detailElectron beam welding machine at Accurate Welding Services
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