Microwave Component Fabrication using the Fast Combustion Driven Compaction Process

70556S02-II Next generation microwave power components, used in conventional and superconducting accelerators, require cost-effective fabrication into various geometrical shapes, tight tolerances for surface quality/dimensions, excellent leak resistance, improved electrical conductivity, and better dielectric behavior under radio frequency (RF) conditions. Conventional manufacturing processes like casting, forging, rapid prototyping, and electroforming have process limitations that make them either technically inadequate or economically unviable for the production of large batches of such components. This project will develop a new, cost-effective, powder metal compaction technology, Combustion Driven Compaction (CDC), for making near-net-shape parts, dramatically improving the surface quality, durability, and performance of these components. Phase I demonstrated the feasibility of the CDC process to fabricate copper, Stainless Steel 316L, and Cu/AlN functional gradient materials (FGM) in various geometries, with improved mechanical strength, surface finish, electrical conductivity, and helium leak resistance. Phase II will further develop the CDC processing for other RF candidate materials such as OFHC Copper, SS316L, W, Mo, and W/Mo/AlN-Glassy Carbon functional gradient ¿artificial dielectric¿composite materials. Sample geometries will include both small-scale R&D samples, such as cylinders and dogbones, as well as larger parts similar to the Next Generation Linear Collider¿s copper disk structure. Commercial Applications and Other Benefits as described by awardee: Commercial applications for the Combustion Driven Compaction technology should include significantly improved components for microwave appliances, cutting tools, metal forming dies, mold inserts, vacuum seals, x-ray tube anode targets, conducting/superconducting accelerators, microelectronic packaging, microwave appliances, cutting tools, superconducting magnets, nuclear fuel cladding, military weapons/ammunition, thermal protection/heat sinks for missiles, bearings, and automotive and aerospace engine parts.