Microwave Component Fabrication using the Fast Combustion Driven Compaction Process

70556 Next generation microwave power components, needed for high energy physics experiements, will be of various shapes and may require demanding tolerances for dimensions, finishes, leak rates, radio frequency (rf) voltage hold-off, and surface conductivity. Conventional manufacturing processes such as casting and electroforming are neither adequate nor economically viable for the production of large batches of these components. Powder metal has been used for many years in many applications. This project will further develop a new powder metal compaction technology, Combustion Drive Compaction, for making nearly net shape microwave power components. Phase I will demonstrate that materials compacted in the Combustion Drive Compaction process can meet the stringent requirements for high power microwave applications. These requirements include demanding dimensional tolerances, very fine surface finishes, the ability to hold high vacuums, the ability to sustain high rf voltage hold-off, and the ability to produce highly conductive materials. Commercial Applications and Other Benefits as described by the awardee: The Combustion Drive Compaction technology should significantly improve components for microwave appliances, cutting tools, metal forming dies, mold inserts, and other components exposed to high temperature and high wear.