Advance Additive Manufacturing Method for SRF Cavities of Various Geometries

Current state-of-the-art SRF accelerating cavities require the use of many complex and expensive techniques throughout their fabrication/performance cycle. This project will utilize a novel Additive Manufacturing (AM) process to produce nearly monolithic SRF niobium cavities of arbitrary shape with features such as optimized wall thickness and/or integrated stiffeners, greatly reducing the cost and technical variability of conventional cavity construction. EBM AM niobium material samples have been successfully fabricated and characterized in Phase I. Conceptual designs exploiting EBM AM have been created. Hardware improvements to AM platform have been studied and proposed. Hardware upgrades to the AM platform will be carried out and characterized in Phase II. A prototype EBM Cavity suitable for high power testing will be fully cost-performance optimized through multi-physics simulationsto take advantage of AM technologyand fabricated. High power testing will be carried out at JLab to characterize EBM Cavity performance. Commercial Applications and Other Benefits: The AM manufacturing approach developed in this project can be applied to SRF cavities and other SRF components used in SRF accelerators in: energy recovery linacs (ERLs), linear colliders (ILC), neutrino factories, spallation neutron sources, and rare isotope accelerators used in medicine, as well as imaging/analysis applications to homeland security.