63
Microwave
Component Fabrication Using the Fast, Combustion Driven Compaction Process--UTRON,
Inc., 8506 Wellington Road, Suite 200, Manassas, VA
20109-3915; 703-369-5552, www.utroninc.com
Dr.
F. Douglas Witherspoon, Principal Investigator,
Dr.
F. Douglas Witherspoon, Business Official,
DOE
Grant No. DE-FG02-02ER83567
Amount:
$749,669
Next
generation microwave power components, used in conventional and superconducting
accelerators, require cost-effective fabrication into various geometrical
shapes, tight tolerances for surface quality/dimensions, excellent leak
resistance, improved electrical conductivity, and better dielectric behavior
under radio frequency (RF) conditions. Conventional
manufacturing processes like casting, forging, rapid prototyping, and
electroforming have process limitations that make them either technically
inadequate or economically unviable for the production of large batches of such
components. This project will
develop a new, cost-effective, powder metal compaction technology, Combustion
Driven Compaction (CDC), for making near-net-shape parts, dramatically improving
the surface quality, durability, and performance of these components.
Phase I demonstrated the feasibility of the CDC process to fabricate
copper, Stainless Steel 316L, and Cu/AlN functional gradient materials (FGM) in
various geometries, with improved mechanical strength, surface finish,
electrical conductivity, and helium leak resistance. Phase
II will further develop the CDC processing for other RF candidate materials such
as OFHC Copper, SS316L, W, Mo, and W/Mo/AlN-Glassy Carbon functional gradient
“artificial dielectric”composite materials. Sample
geometries will include both small-scale R&D samples, such as cylinders and
dogbones, as well as larger parts similar to the Next Generation Linear
Collider’s copper disk structure.
Commercial Applications and Other
Benefits
as described by awardee: Commercial
applications for the Combustion Driven Compaction technology should include
significantly improved components for microwave appliances, cutting tools, metal
forming dies, mold inserts, vacuum seals, x-ray
tube anode targets, conducting/superconducting accelerators, microelectronic
packaging, microwave appliances, cutting tools, superconducting magnets, nuclear
fuel cladding, military weapons/ammunition, thermal protection/heat sinks for
missiles, bearings, and automotive and aerospace engine parts.