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Additive Manufacturing for X-band applications

Additive Manufacturing for X-band applications

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Additive Manufacturing for X-band applications

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  1. Additive Manufacturing for X-band applications Alexej Grudiev 5/02/2014 CLIC14 workshop

  2. Acknowledgements • BE-RF • Miriam Colling • Alexej Grudiev • EN-MME • Said Atieh • Ofelia Capatina • Floriane Leaux • Raphael Leuxe • Thomas Sahner • Ignacio Santillana • TE-VSC • Sergio Calatroni • Ivo Wevers

  3. Additive manufacturing Process Model designed in CAD CAD file sent to additive manufacturing system Model divided into slices 3D product sculpted from powdered material layer by layer using the specified technique EOS – SLS, http://www.eos.info/additive_manufacturing/for_technology_interested

  4. Number of good reasons to try

  5. Typical materials

  6. Technical data Ti64 Ti64 DC electrical conductivity: 600000 S/m, two times lower than stainless steel • Relatively low accuracy • Big roughness (much larger than skin depth) • Low DC conductivity Obvious RF application is a broad-band all-metal dry RF load

  7. High power/E-field performance of Ti 30 GHz high power performance, PAC2007 DC breakdown thresholds

  8. Three stages of the project • Low power prototype for material and fabrication characterization • DC conductivity and RF losses • UHV compatibility: leak tightness and outgassing • Shape accuracy and Roughness • Mechanical strength and Metallurgy • Prototypes for high power tests • Integration of cooling • High power performance • Design of the RF load • RF load prototype We are here

  9. Prototype Design • Prototype modelled in HFSS • WR90 end tapered to 13mm by 2mm middle 200mm

  10. Waveguide manufacturing methods Waveguide 1: EOS – Selective laser sintering Waveguide 2: Grenoble INP – Electron beam melting 5 Waveguides 3, 4 and 5: Concept – Selective laser melting • Length: 20cm • Material: Titanium alloy

  11. RF measurements using VNA • Obtained data for S(1,1), S(1,2), S(2,1) and S(2,2) parameters for each of the five waveguides • Measurements required careful handling - movement in cables cause readings to change • Measurements repeated three times for each waveguide for reliable results

  12. RF Results Comparison of S(1,1) parameter

  13. RF Results Comparison of S(1,2) parameter

  14. DC conductivity measurements Titanium alloy conductivity: 6E+5 S/m Two types of DC measurements: • Four probes in contact with middle section • Two probes in contact with middle while clamps on flange provide voltage difference 6mm 62mm

  15. DC Results Titanium alloy conductivity: 6E+5 S/m Method 1 Method 2 Apply all DC cond. to HFSS waveguide and obtain values for all 3 parameters in each case aqw a Nominal HFSS values: ‘aqw’=14.2mm ‘a’=13mm Roughness=0µm

  16. Determining parameters

  17. Determining parameters

  18. Table of parameters HFSS Nominal: a=‘13mm’ aqw=‘14.2mm’ rough=‘0um’ • Tables show: • Values for each modified parameter: ‘a’ , ‘aqw’ and HFSS roughness • 100-300 micron differences • Change in parameters required to provide HFSS results which agree with those produced by the VNA for each waveguide

  19. Metrology Microtomography – X-ray non destructive testing 1 Radioscopic image acquisition 2 3D reconstruction 3 Post processing Images: RX solutions gallery http://www.rxsolutions.fr/#!untitled/zoom/cjjm/i47og1

  20. Metrology Results • Blue lines show lack of material • Red lines show excess material

  21. Metrology Results • First three waveguides were measured using microtomography to determine dimensions ‘a’ and ‘aqw’ • Measured ‘a’ at 3 points and ‘aqw’ and 2 points and an average was found • Waveguide 1 and 3 < 100micron difference from nominal RF+DC measurements:

  22. Vacuum • Waveguide 1, 3,4 and 5 are leak tight, OK for UHV • Waveguide 2 was not be able to pump down due to presence of small holes

  23. Mechanical testing and metallographic observations Waveguide 2 Waveguide 3 Waveguide 1 Before etching After etching W1 shows least porosity W2 shows large porosity W3 shows different microstructure

  24. Summary of the results obtained after tensile tests of the samples OK OK

  25. Summary • Laser melting fabrication is validated for two manufacturers • EBM fabrication requires some improvements • Next step: