3D Printed Bimetallic Structures for Radio Frequency Devices, Topic 34a

C53-34a-271222During Phase I of this DOE SBIR program, NanoSonic addressed two opportunities identified by the Office of Nuclear Physics community regarding advanced materials for superconducting radio frequency components within particle accelerators. Specifically, NanoSonic developed new cost- effective bimetallic structure forming techniques as well as void-free, non-offgassing, additively manufacturable radiation durable polymers. During Phase I of this program, NanoSonic demonstrated that our low glass temperature (Tg), cryogenically resilient, yet high temperature durable polymers could be compounded with radiation resistant constituents in our twin-screw extruder using zero solvent – as films, filaments for 3D printing, or pellets for molding. Moreover, we demonstrated that the resultant radiation resistant composite could indeed be injection molded. During Phase I of this SBIR program, NanoSonic has designed, physically developed, and tested radiation durable, zero offgassing, additively manufactured composites and 3D printed bimetallic structures using cost effective binder jet methodology. Each of these developments shall be expanded upon and investigated in a real-world environment at Jefferson Lab during Phase II. During Phase II, the new radiation tolerant polymers for use within metallic gate valve housings shall be produced via reactive extrusion to replace o-rings that currently degrade through radiation induced brittle failure. Mechanical properties of the new bimetallic radio frequency structures and gate valve polymers shall be tested before and after irradiation at BNL NSRL, VPTRad, and Jefferson Laboratory. The polymers sealing capacity shall be tested after irradiation in the CEBAF for the representational environment study to reach TRL 7. Three dimensional bimetallic structures and polymer o-rings would be formed as part of the manufacturing feasibility plan. A commercialization strategy to reach Technology Readiness Level 9 in Phase II shall be established with integration partners to ultimately integrate the gate valves within CEBAF. New high radiation durable composites shall be used as replacements for Viton within gate valves for the cryomodules in Jefferson Laboratory’s CEBAF. A broader market can be addressed with the solvent and void-free, non-outgassing radiation durable extruded filaments and pellets for 3D printed materials and injection molded structures.