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

The Department of Energy’s Office of Nuclear Physics and members of the superconducting radio frequency accelerators community have identified a need for new high radiation durable materials. The goal for this program is to develop new bimetallic structures for radio frequency devices and polymers for gate valves that survive krad levels of radiation over a 2-year period. The objective of this program is to develop and demonstrate advanced, cost-effective, high radiation tolerant bimetallic materials and polymers through additive and scalable manufacturing methods. The proposed innovations for this program involve a novel metal forming technique to eliminate beam welds via binder jet printing and the reactive extrusion of rad hard polymers for peripheral components. In Phase I, a novel technique for binder jet printing will be used with an ExOne system to yield new bimetallic coupons for a radiation exposure study. An innovative approach shall be used during the depowdering and hydrogen sintering steps in the bimetallic structure process to achieve high densities close to that of bulk metals to reach a Technology Readiness Level 4. Additionally, 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 for a benchmark study to reach TRL 5. Three dimensional bimetallic structures and polymer o-rings would be formed as part of the manufacturing feasibility plan. A strategy to reach Technology Readiness Level 7 in Phase II shall be established with integration partners to ultimately integrate the gate valves within a particle accelerator at a national laboratory. The bimetallic structures formed via binder jet printing offer the potential for significant cost reductions by simplifying cavity dumbbells and end groups and may eliminate the need for electron beam welds. The rad hard polymer o-rings would be used in peripheral components for superconducting structures, such as gate valves, as discussed with members of the accelerator community.