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Description
Additive Manufacturing (AM) enables innovative design strategies for accelerator components by allowing the integration of complex internal features such as conformal cooling channels. Recent development work on ISIS initially focused on a 3D-printed cooling jacket with racetrack cooling geometry fabricated using Selective Laser Sintering (SLS) of glass-filled Nylon, which provided confidence to extend the approach to metal AM. Subsequent efforts employed Direct Metal Laser Sintering (DMLS) of stainless-steel beam dump and further led to the development of an ion source main flange incorporating intricate cooling channels. A full scale metal AM prototype of the flange was successfully fabricated, precision post-machined, and validated using neutron imaging on the IMAT instrument at ISIS, confirming accurate placement and integrity of the internal channels.
Future work focuses on ceramic AM for plasma chamber applications in ion sources, by integrating the cooling channel into the ceramic plasma chamber wall, thereby allowing the RF coil to be positioned closer to the plasma. A proof-of-concept ceramic prototype has been produced, demonstrating the potential for enhanced thermal and RF - plasma coupling efficiency. Further performance gains are now being explored through multi-material 3D printing, particularly ceramic-copper combinations, to enable next-generation accelerator structures with better thermal management and performance improvements.
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