DMS-South/Bailey Tool LLC — Department of Energy SBIR Phase I: 33a

Description

Bellows for particle accelerators are currently manufactured using precision welding assembly and on some occasions require copper plating. Successful plating is challenging when considering complications of internal bellows surfaces and the technical challenges of metal-electro-deposition processes. Coating variability and flaking of coatings in situ are common and represent expensive failure modes. The objective of this project is to develop methods to substitute a more robust deposition process for final copper coatings. Tubular deep-draw and hydroforming processes will be employed. A cladding process between stainless and copper sheets with subsequent conversion to tubes for hydroforming will be used to apply copper to the bellows which can be fine-tuned in thickness by electro-polishing after final assembly. Bellows forming processes will be designed and developed based on experience in deep- drawing and hydroforming processes derived from manufacturing superconducting radio frequency cavities. Tailored cladding will be developed for application of copper layers to stainless or other substrates. Finite element analysis will be used as needed to predict, trouble-shoot and validate forming processes. Prototype tooling will be designed and built and sample forming and cladding trials will be conducted to develop optimal manufacturing processes. Finally, reduced scale finished samples will be submitted to Jefferson Lab for review and characterization. Improving the quality and cost of U.S.-produced particle accelerator and vacuum system components would have a meaningful impact on domestic capacity to participate in the growing global construction of accelerator systems for scientific and industrial uses. A decline in the US industrial base inthese sectors could be reversed by successful development and marketing of novel and improved copper deposition methods and other future developments. Successful execution has broad commercial application on a global scale.