Near Net Shape Manufacturing Using Combustion Driven Compaction

73102S03-I The Department of Energy seeks innovative manufacturing processes to produce copper components for use in high-power microwave applications. This project will identify, and optimize, key process parameters for the near-net-shape manufacturing and materials characterization of Oxygen-Free High Conductivity (OFHC) copper disks, produced by the Combustion-Driven Compaction (CDC) of metallic powders. These copper disks are very important in linear accelerators, such as the Next Linear Collider (NLC), for delivering intense radio frequency (RF) microwave power to the beam. The proposed technique will be cost-effective and competitive with other traditional processes, such as casting/forging, in terms of improved product quality, surface/geometrical tolerances, and superior properties. Phase I will demonstrate the uniqueness of CDC processing, used to develop the specific structure of NLC copper-disks. Structure/property relationships will be optimized for improving disk density, microstructure, surface finish, product quality, mechanical behavior/electrical conductivity, brazability, and geometrical tolerance. Commercial Applications and Other Benefits as described by awardee: Commercial applications of the CDC process should include cost-effective manufacturing of RF microwave parts, x-ray/sputtering targets, vacuum seals for accelerators, cryogenic components, high temperature heat shields/tiles for missiles/rockets, nuclear storage pellets, military ammunitions, bearings, valves/valve seats, piston-rings, pump covers, superconducting magnets, dies/molds, cutting tools, Functionally Gradient Materials, and dissimilar/difficult-to-weld material bonding.