Advanced and Additive Materials Manufacturing for Energy Applications using Superconducting Electron Beam Technology

Subsequent Phase II Proposal, extension of Phase II contract N0014-12-C-0373. High power, superconducting electron linear accelerators represent a new method of producing highly focused electron beams (Ebeams). These instruments have exciting applications in the area of free electron lasers and directed energy weapons, but are costly and currently only useful in small, highly-specialized markets. Using these high energy Ebeams for materials processing opens up additional markets for these instruments and in turn lower their manufacturing costs. In Phase I, Mainstream identified several materials processes that could be uniquely improved by the use of Ebeam treatment. In an initial Phase II, a new type of superconducting electron linear accelerator was procured in order to demonstrate the economical production of diamond copper composite heat spreaders. This subsequent Phase II will enable this Ebeam to also be demonstrated in the fabrication of copper indium gallium selenide nanocrystal films for advanced solar cells. Additionally, this Phase II will facilitate the commissioning of an advanced manufacturing facility at Mainstream, with the Ebeam as the centerpiece. The resulting Ebeam facility will establish a marketplace for these highly specialized Ebeams as well as produce several exciting new materials at the pilot-scale with both military and commercial applications.