Additive manufacturing (AM) of metals has the potential to provide significant benefits for the construction of future particle accelerators. The combination of low cost manufacturing of complex geometries in combination with efficiency gains from improved linac design enabled by AM may be one way towards future cost-effective green accelerator facilities. As a proof of concept, we present a high-efficiency Zeff=280 MΩ/m, 433.632 MHz IH-DTL cavity based on an AM design. In this case, the complex internal drift tube structures with internal cooling channels have been produced from 1.4404 stainless steel and from pure copper using AM. The prototype cavity, as well as stainless steel AM parts have been electroplated with copper. We present results from successful vacuum tests, low level RF measurements of the cavity, as well as the status of preparations for high-power RF tests with a 30 kW pulsed power amplifier. 

Additive Manufacturing of an IH-Type Linac Structure from Stainless Steel and Pure Copper

Due to the interference of ambient wind on arc burning and droplet transfer, wire arc additive manufacturing (WAAM) of aluminum alloy in field environment is hindered. The gas-slag joint protection by synchronous feeding of AlSi5 wire and mixed powder of 90Mg-5TiO2-5NaF (wt.%) was introduced. It was found the wind resistance for the stable deposition of thin-wall could be improved from 1.5 to 3.5 m/s. The added Mg benefited to refine the grain size by 21% and promote the formation of Mg2Si, which improved the mechanical properties by induced solid solution-precipitation strengthening effects. Furthermore, with the assistance of laser cleaning, the porosity of thin-wall deposited at ambient wind speed of 3.5 m/s was reduced from 54.9% to 28%. These improvements increased the ultimate tensile strength and elongation to 166 MPa and 3.7%, reaching 98.2% and 31% of the WAAM at indoor windless environment respectively. 

Laser cleaning assisted wire arc additive manufacturing of aluminum alloy thin-wall through synchronous wire-powder deposition

Compared to conventional manufacturing, additive manufacturing (AM) of radio frequency (RF) cavities has the potential to reduce manufacturing costs and complexity and to enable higher performance. This work evaluates whether normal conducting side-coupled linac structures (SCCL), used worldwide for a wide range of applications, can benefit from AM. A unit cell geometry (SC) optimized for 75 MeV protons was developed. Downskins with small downskin angles α were avoided to enable manufacturing by laser powder bed fusion without support structures. SCs with different α were printed and post-processed by Hirtisation (R) (an electrochemical process) to minimize surface roughness. The required accuracy for 3 GHz SCCL (medical linacs) is achieved only for α>45∘. After a material removal of 140 µm due to Hirtisation (R), a quality factor Q0 of 6650 was achieved. This corresponds to 75% of the Q0 simulated by CST®. A 3 GHz SCCL concept consisting of 31 SCs was designed. The effective shunt impedance ZT2 simulated by CST corresponds to 60.13MΩm and is comparable to the ZT2 of SCCL in use. The reduction in ZT2 expected after Hirtisation (R) can be justified in practice by up to 70% lower manufacturing costs. However, future studies will be conducted to further increase Q0.

Additive Manufacturing of Side-Coupled Cavity Linac Structures from Pure Copper: A First Concept

As humankind prepares to establish outposts and infrastructure on the Moon, the ability to manufacture parts and buildings on-site is crucial. While transporting raw materials from Earth can be costly and time-consuming, in-situ resource utilization (ISRU) presents an attractive alternative. This review paper aims to provide a thorough examination of the current state and future potential of Lunar-based manufacturing and construction (LBMC), with a particular focus on the prospect of utilizing in-situ resources and additive manufacturing. The paper analyzes existing research on LBMC from various perspectives, including different manufacturing techniques and compositions, the potential of ISRU for LBMC, characterization of built parts and structures, the role of energy sources and efficiency, the impact of low-gravity and vacuum conditions, and the feasibility of using artificial intelligence, automation, and robotics. By synthesizing these findings, this review offers valuable insights into the challenges and opportunities that lie ahead for LBMC.

A comprehensive review of lunar-based manufacturing and construction

Enhanced electrical and mechanical properties of additively manufactured pure copper with green laser

A multidisciplinary collaboration within the I.FAST project teamed-up to develop additive manufacturing (AM) technology solutions for accelerators. The first prototype of an AM pure-copper Radio Frequency Quadrupole (RFQ) has been produced, corresponding to ¼ of a 4-vane RFQ. It was optimised for production with state-of-the-art laser powder bed fusion technology. Geometrical precision and roughness of the critical surfaces were measured. Although the obtained values were beyond standard RFQ specifications, these first results are promising and confirmed the feasibility of AM manufactured complex copper accelerator cavities. Therefore, further post-processing trials have been conducted with the sample RFQ to improve surface roughness. Algorithms for the AM technological processes have also been improved, allowing for higher geometrical precision. This resulted in the design of a full 4-vane RFQ prototype. At the time of the paper submission the full-size RFQ is being manufactured and will undergo through the stringent surface quality measurements. This paper is discussing novel technological developments, is providing an evaluation of the obtained surface roughness and geometrical precision as well as outlining the potential post-processing scenarios along with future tests plans.

https://doi.org/10.1088/1742-6596/2420/1/012089

Evaluation of geometrical precision and surface roughness quality for the additively manufactured radio frequency quadrupole prototype

The internal ion source of the Advanced Molecular Image Technologies (AMIT) superconducting cyclotron uses cathodes made of pure tantalum to generate high energy H− ion beams for the production of isotopes for positron emission tomography. During service, the cathodes are impacted by high-energy ions from the plasma. The resulting erosion creates craters that reduce the current density of the extracted beam. The cathodes eventually need to be replaced when the ion source can no longer be activated. This research explores the possibility of repairing the tantalum cathodes used in the AMIT cyclotron through laser metal deposition additive manufacturing. The damaged parts were first characterised by 3D imaging, scanning electron microscopy, and Vickers microhardness to understand the damage mechanisms occurring during service and quantify the extent of the damage. Different repair strategies were then tested employing both high-purity tantalum wire and powder feedstocks and the properties of the reconditioned electrodes were determined. The ability of laser metal deposition to restore the damaged cathodes for use in the AMIT cyclotron has been demonstrated. 

Damage characterisation of tantalum ion source electrodes and reconditioning by wire- and powder-based laser metal deposition

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Evaluation of geometrical precision and surface roughness quality for the additively manufactured radio frequency quadrupole prototype

Damage characterisation of tantalum ion source electrodes and reconditioning by wire- and powder-based laser metal deposition