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• W4244741602 abstract "exhibiting features, such as corrugations, with significantly smaller dimensions. However, traditional manufacturing approaches are inadequate, in terms of manufacturing precision and cost, to meet these requirements. Thus, to satisfy the purity and dimensional tolerance requirements of waveguides operating at high frequencies, novel fabrication techniques are required. In this SBIR program, Faraday Technology in consultation with Argonne Wakefield Accelerator (AWA) group, addressed this need by developing an economic fabrication process and apparatus for electroforming high-purity cylindrical copper waveguides with internal corrugations. Research Carried Out In this Phase I DOE SBIR program, Faraday Technology investigated a unique electroforming approach for fabricating 26 GHz high-purity copper waveguides designed by the Argonne Wakefield Accelerator (AWA) group. Accordingly, Faraday Technology and AWA demonstrated the potential of a scalable, accurate, and cost-effective, pulse-modulated electroforming process by: Designing and machining the 26 GHz waveguide structure Designing and building electroforming apparatus Evaluating the electroforming performance via microscopy & profilometry cross-sectioned copper electroforms Evaluating the waveguide cold test results and comparison to simulated performance Analyzing the technical and economic viability of electroforming to traditional direct-contact strategies for waveguide fabrication. Research Findings Within this Phase I DOE SBIR program, Faraday Technology and AWA demonstrated: A scalable, accurate, and cost-effective pulse-modulated electroforming process for fabrication of high-purity cylindrical copper waveguides with internal corrugations. The pulse-modulated electroforming process promoted better adhesion and facilitated complete coverage of the mandrel when compared to DC operation at the same current density. Positive correlation between pulse waveform frequency and copper filling of corrugation valleys Transferrable shape fidelity and dimensional accuracy between mandrel and copper waveguide Results of cold tests conducted at AWA concluded that the fabricated 50-mm short structure shows a reasonable agreement with the design by CST simulation, which validates the novel fabrication method. The optimized pulse waveform is applicable/scalable from 2-inch to 6-inch mandrel Potential Applications Successful implementation of this technology would result in the reliable, reproducible, and economic production of oxygen-free copper waveguides with internal corrugation features enabling and advancing microwave technology for the generation, amplification, and/or transmission of higher than conventional frequencies (e.g., 30 GHz – 300 GHz), electron accelerators for beam manipulation, and novel Wakefield accelerators. This technology could result in additional advancements towards even higher frequencies that could benefit military, commercial, and civilian telecommunications, plasma diagnostics and heating of fusion plasmas (for fusion energy reactors), as well as spectroscopic identification and imaging in security and medicine." @default.
• W4244741602 created "2022-05-12" @default.
• W4244741602 creator A5038881587 @default.
• W4244741602 date "2003-06-03" @default.
• W4244741602 modified "2023-10-17" @default.
• W4244741602 title "Development of millimeter-wave accelerating structures using precision metal forming technology" @default.
• W4244741602 doi "https://doi.org/10.2172/819048" @default.
• W4244741602 hasPublicationYear "2003" @default.
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