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Seamless SRF Cavity Fabrication by Spin-Necking and Hydroforming

Award Information

Agency:
Department of Energy
Branch:
N/A
Award ID:
Program Year/Program:
2013 / SBIR
Agency Tracking Number:
84196
Solicitation Year:
2013
Solicitation Topic Code:
34 b
Solicitation Number:
DE-FOA-0000760
Small Business Information
Bailey Tool & Mfg. Co.
600 W. Belt Line Road Lancaster, TX 75146-3019
View profile »
Woman-Owned: No
Minority-Owned: No
HUBZone-Owned: No
 
Phase 1
Fiscal Year: 2013
Title: Seamless SRF Cavity Fabrication by Spin-Necking and Hydroforming
Agency: DOE
Contract: DE-FG02-13ER90558
Award Amount: $150,000.00
 

Abstract:

Superconducting radio frequency (SRF) cavities for use in the International Linear Collider (ILC) are currently fabricated by electron-beam welding of press-formed half-cell cups. Cavities produced in this method experience weld-related defects that limit accelerator performance and increase the cost of supplying the SRF system to the end user. E-beam welding in its optimum state is expensive and causes additional manufacturing risk and lead time. This project will develop a weld-free cavity forming process which will eliminate welds and weld-related defects and therefore reduce cavity cost. The primary reference model will be the 1.3 GHz 9-cell TESLA-style SRF cavity but the objective will be to produce a 3-cell cavity. The sequential forming processes of spin-necking and hydroforming will be employed to produce cavities from a single, weld-free tube of cavity metal. Cavity irises and equators will be mechanically formed on a spinning machine and ultimately a hydroforming press to produce final cavity geometry. Copper will be employed for this Phase I project. The Work Plan objective is to produce a spin- necked perform portion of the seamless cavity forming process, leaving the hydroform stage to a Phase II work plan. However, hydroform tooling system design will be performed in the Phase I Work Plan so that the system will be ready for construction in the proposed Phase II and III commercialization stages of the project. The Phase I Work Plan will verify methods development previously performed by Proposer through numerical analysis of spin-necking and hydroforming and then operate a spin-necking process to produce a spin-necked tube, ready for the subsequent hydroform process.

Principal Investigator:

Woong Ho Bang
Dr.
4699160107
whbang@baileytool.com

Business Contact:

John S. Buttles
Mr.
jbuttles@baileytool.com
Small Business Information at Submission:

Bailey Tool & Mfg. Co.
600 W. Belt Line Road Lancaster, TX 75146-3019

EIN/Tax ID: 752459873
DUNS: N/A
Number of Employees:
Woman-Owned: No
Minority-Owned: No
HUBZone-Owned: No