RF Properties and Their Variations in a 3D Printed Klystron Circuit and Cavities

Presently, the manufacturing of active RF devices like klystrons is dominated by expensive and time consuming cycles of machining and brazing. In this article we characterize the RF properties of X-band klystron cavities and an integrated circuit manufactured with a novel additive manufacturing process. Parts are 3D printed in 316L stainless steel with direct metal laser sintering, electroplated in copper, and brazed in one simple braze cycle. Standalone test cavities and integrated circuit cavities were measured throughout the manufacturing process. Un-tuned cavity frequency varies by less than 5% of intended frequency, and Q factors reach above 1200. A tuning study was performed, and unoptimized tuning pins achieved a tuning range of 138 MHz without compromising Q. Klystron system performance was simulated with as-built cavity parameters and realistic tuning. Together, these results show promise that this process can be used to cheaply and quickly manufacture a new generation of highly integrated high power vacuum devices.Comment: 8 pages, 16 figure

Utilization of Additive Manufacturing for the Rapid Prototyping of C-Band RF Loads

Additive manufacturing is a versatile technique that shows promise in providing quick and dynamic manufacturing for complex engineering problems. Research has been ongoing into the use of additive manufacturing for potential applications in radiofrequency (RF) component technologies. Here we present a method for developing an effective prototype load produced out of 316L stainless steel on a direct metal laser sintering machine. The model was tested within simulation software to verify the validity of the design. The load structure was manufactured utilizing an online digital manufacturing company, showing the viability of using easily accessible tools to manufacture RF structures. The produced load was able to produce an S$_{11}$ value of -22.8 dB at the C-band frequency of 5.712 GHz while under vacuum. In a high power test, the load was able to terminate a peak power of 8.1 MW. Discussion includes future applications of the present research and how it will help to improve the implementation of future accelerator concepts

Utilization of Additive Manufacturing for the Rapid Prototyping of C-Band Radiofrequency Loads

Additive manufacturing is a versatile technique that shows promise in providing quick and dynamic manufacturing for complex engineering problems. Research has been ongoing into the use of additive manufacturing for potential applications in radiofrequency (RF) component technologies. Here, we present a method for developing an effective prototype load produced from 316L stainless steel on a direct metal laser sintering machine. The model was tested using simulation software to verify the validity of the design. The load structure was manufactured by an online digital manufacturing company, showing the viability of using easily accessible tools to manufacture RF structures. The produced load was able to produce an S11 value of −22.8 dB at a C-band frequency of 5.712 GHz while under a vacuum. In a high-power test, the load was able to terminate a peak power of 8.1 MW. The discussion includes future applications of the present method and how it will help to improve the implementation of future accelerator concepts