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A variety of studies show that additive manufacturing (AM) of particle-accelerator components using laser powder bed fusion (PBF-LB/M) offers significant potential to reduce investment costs while simultaneously improving figures of merit. However, the classical PBF-LB/M process does not support combining different materials within a single piece. Conventional manufacturing routines are therefore still required, for example, to join steel flanges with knife-edge sealing interfaces to copper cavities. A novel multi-material (MM) PBF-LB/M process now enables the fabrication of high-quality (e.g., high-density) geometries by combining different materials such as Cu, CuCr1Zr, Ta, W, aluminum alloys, or stainless steel. Highly functional parts tailored to the diverse requirements of accelerator components can now be additively manufactured within a single process step. To demonstrate this potential for the first time, we fabricated a monolithic RFQ prototype from two different materials using MM PBF-LB/M. The RFQ’s inner cavity is manufactured from CuCr1Zr, enabling a complex, near-surface cooling system, while the co-printed outer shell is made of tool steel to integrate two CF63 and four CF16 flanges. The inner cavity surface was electropolished and subsequently copper plated to increase the quality factor. Low-level RF measurements match the performance predicted by CST simulations. The Helium leak rate is equivalent to those of conventionally manufactured RFQ cavities.
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