Public Abstract

DE-SC0025364: Multi-physics driven fabrication of next generation SRF structures

Award Status: Active

Institution: The Ohio State University, Columbus, OH
UEI: DLWBSLWAJWR1
DUNS: 832127323

Most Recent Award Date: 09/05/2024
Number of Support Periods: 1
PM: Ginsburg, Camille

Current Budget Period: 09/01/2024 - 08/31/2025
Current Project Period: 09/01/2024 - 08/31/2027
PI: Panton, Boyd

Supplement Budget Period: N/A

Public Abstract

The objective of this proposal is to establish a fundamental understanding of welding and forming processes of sheet materials that are used to produce superconducting radio-frequency (SRF) cavities. The research will study niobium which is proposed by JLab as of their immediate interest. Five research tasks are envisioned: Task 1 will characterize the electron beam and process at JLab, to enable accurate process modeling and control, and to build a scientific understanding of the electron beam welding process and the weldability of niobium; Task 2 will establish the mechanical properties of niobium that are relevant to forming and joining, and will build predictive modeling tools (both phenomenological and microstructurally-informed); Task 3 will establish the formability of niobium and using the tools from Task 2 it will build a scientific understanding of sheet forming; Task 4 will manufacture and test a full scale SRF cavity prototype; Task 5 will advance workforce development of the next generation of SRF scientists. Due to the high cost of niobium the research has been designed around novel experiments that will yield the necessary information but with much-reduced requirements on raw materials. These experiments will be supplemented by powerful modeling tools (both phenomenological and microstructural), that can yield quantitative predictions in forming and welding. The research will be a close collaboration between the Ohio State University (OSU) and the Thomas Jefferson National Accelerator Facility (JLab). The OSU researchers have expertise in electron beam welding, forming, solid mechanics and materials science, and so they are well-positioned to tackle this research. The JLab team will offer its expertise on SRF cavity design, and most importantly on all the fabrication, including welding and forming, challenges that they have been facing for years. The team will also receive expert assistance by RadiaBeam Technologies (RBT) in forming and welding of the materials of this study, thus maintaining an open channel to an industry partner who can benefit from this research to enable domestic series production of SRF cavities. The present work will build on the fundamental advancements in understanding the behavior of niobium that DoE/SC has been supporting and will establish the science necessary to enable sheet forming and electron beam welding. These aspects will complement other DoE/SC efforts and will serve as the bridge between the advancements in niobium metallurgy and the fabrication of SRF cavities. This research will establish scientific-evidence-based data and tools to rationalize the design of welding and forming of SRF cavities and cryomodules. It will also train scientists and manufacturing engineers tuned to SRF cavity fabrication issues, including underrepresented minorities as outlined in the PIER plan and evidenced by the track record of the PIs.

The objective of this proposal is to establish a fundamental understanding of welding and forming processes of sheet materials that are used to produce superconducting radio-frequency (SRF) cavities. The research will study niobium which is proposed by JLab as of their immediate interest. Five research tasks are envisioned: Task 1 will characterize the electron beam and process at JLab, to enable accurate process modeling and control, and to build a scientific understanding of the electron beam welding process and the weldability of niobium; Task 2 will establish the mechanical properties of niobium that are relevant to forming and joining, and will build predictive modeling tools (both phenomenological and microstructurally-informed); Task 3 will establish the formability of niobium and using the tools from Task 2 it will build a scientific understanding of sheet forming; Task 4 will manufacture and test a full scale SRF cavity prototype; Task 5 will advance workforce development of the next generation of SRF scientists. Due to the high cost of niobium the research has been designed around novel experiments that will yield the necessary information but with much-reduced requirements on raw materials. These experiments will be supplemented by powerful modeling tools (both phenomenological and microstructural), that can yield quantitative predictions in forming and welding.

The research will be a close collaboration between the Ohio State University (OSU) and the Thomas Jefferson National Accelerator Facility (JLab). The OSU researchers have expertise in electron beam welding, forming, solid mechanics and materials science, and so they are well-positioned to tackle this research. The JLab team will offer its expertise on SRF cavity design, and most importantly on all the fabrication, including welding and forming, challenges that they have been facing for years. The team will also receive expert assistance by RadiaBeam Technologies (RBT) in forming and welding of the materials of this study, thus maintaining an open channel to an industry partner who can benefit from this research to enable domestic series production
of SRF cavities.
The present work will build on the fundamental advancements in understanding the behavior of niobium that DoE/SC has been supporting and will establish the science necessary to enable sheet forming and electron beam welding. These aspects will complement other DoE/SC efforts and will serve as the bridge between the advancements in niobium metallurgy and the fabrication
of SRF cavities.
This research will establish scientific-evidence-based data and tools to rationalize the design of welding and forming of SRF cavities and cryomodules. It will also train scientists and manufacturing engineers tuned to SRF cavity fabrication issues, including underrepresented minorities as outlined in the PIER plan and evidenced by the track record of the PIs.