Speaker
Description
Additive manufacturing (AM) enables new design approaches for accelerator components by allowing internal features, such as conformal cooling channels, to be integrated directly into parts. At the ISIS Neutron and Muon Source, development began with a polycarbonate cooling jacket for an RF plasma chamber, later replaced with glass-filled nylon due to sealing limitations. The work was extended to metal AM, including a stainless-steel beam dump produced by direct metal laser sintering (DMLS), demonstrating the need for selective post-machining of sealing surfaces. These lessons informed the design of an ion source main flange with internal cooling channels, successfully prototyped, machined, and validated using neutron imaging at the IMAT instrument. Current research focuses on ceramic AM for plasma chambers, integrating cooling channels within the ceramic wall to allow closer RF coil placement. A digital-light-processing (DLP) printed alumina green-body chamber has been produced as a proof of concept, supporting future development in aluminium nitride (AlN) and multi-material ceramic–copper systems for improved thermal management and performance improvements.
| Paper status | Resubmitted proceeding files received and assigned to an editor. Accepted. |
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