Seamless SRF Cavity Fabrication by Spin-Necking and Hydroforming

Award Information
Agency: Department of Energy
Branch: N/A
Contract: DE-FG02-13ER90558
Agency Tracking Number: 84196
Amount: $150,000.00
Phase: Phase I
Program: SBIR
Awards Year: 2013
Solicitation Year: 2013
Solicitation Topic Code: 34 b
Solicitation Number: DE-FOA-0000760
Small Business Information
600 W. Belt Line Road, Lancaster, TX, 75146-3019
DUNS: 055318612
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Woong Ho Bang
 Dr.
 (469) 916-0107
 whbang@baileytool.com
Business Contact
 John Buttles
Title: Mr.
Phone: () -
Email: jbuttles@baileytool.com
Research Institution
 Stub
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.

* Information listed above is at the time of submission. *

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