SRF e-beam accelerator for metal additive manufacturing

1. A system comprising:

a particle accelerator configured to produce a particle beam the particle accelerator further comprising:

a superconducting cavity;

an electron gun;

a power coupler the power coupler configured to isolate a cavity vacuum inside a superconductor cavity housing with a ceramic window configured to minimize heat flow; and

a beam dump comprising a Faraday cup;

a conduction cooling system configured to conduct thermal energy away from the particle accelerator the conduction cooling system comprising a plurality of cavity coolers that fully encircle each cell of the particle accelerator superconducting cavity cells; and

a manufacturing system wherein the particle beam provides energy to a build chamber of the additive manufacturing system via a flange connecting the manufacturing system to the particle accelerator.

2. The system of claim 1 wherein the particle accelerator comprises one of:

a 650 MHz superconducting radio frequency accelerator with 1.5 cells, operating at 1 MV/m; and

a 1.3 GHz superconducting radio frequency accelerator.

3. The system of claim 2 wherein the superconducting radio frequency accelerator is configured to generate at least a 50 kW beam power at 1 MeV, and a beam current of at least 50 mA in a continuous wave operation.

4. The system of claim 1 wherein the superconducting cavity further comprises:

at least 5 cells.

5. The system of claim 3 wherein the electron gun further comprises one of:

a thermionic cathode, the thermionic cathode being adjacent to a racetrack grid, wherein a cold part of the electron gun is directly exposed to an inside surface of the superconducting cavity; and

a flange connected to the thermionic cathode with an Al diamond gasket.

6. The system of claim 3 wherein the superconducting cavity further comprises:

an Mg 3 B 2 cavity.

7. The system of claim 1 wherein the electron gun further comprises: Tungsten slits configured to control current.

8. The system of claim 7 wherein the manufacturing system comprises an electron beam melting apparatus.

9. The system of claim 8 wherein the electron beam melting apparatus further comprises:

a beam bending assembly configured to adjust a position of the electron beam in the build chamber the beam bending assembly comprising at least one electromagnet and a computer system configured to control the at least one electromagnet;

a build platform configured in the build chamber; and

a powder tank configured to provide powder to the build chamber.

10. The system of claim 1 wherein the conduction cooling system further comprises:

a refrigeration source;

a cavity cooler in conductive contact with the particle accelerator; and

a cooling connector forming a conductive connection between the cavity cooler and the refrigeration source.

11. The system of claim 10 wherein the refrigeration source comprises a cryocooler.

12. A manufacturing system comprising:

a superconducting radio frequency accelerator configured to produce an electron beam;

a conduction cooling system configured to cool the superconducting radio frequency accelerator;

an electron beam melting system wherein the electron beam melts a build material associated with the electron beam melting apparatus; and

a flange connecting the electron beam melting system to the super conducting radio frequency accelerator.

13. The manufacturing system of claim 12 wherein the superconducting radio frequency accelerator further comprises:

a superconducting cavity;

an electron gun;

a power coupler; and

a beam dump comprising a Faraday cup.

14. The manufacturing system of claim 13 wherein the superconducting cavity further comprises:

a niobium cavity with 1.5 cells, operating at 1 MV/m.

15. The manufacturing system of claim 12 wherein the electron beam melting apparatus further comprises:

a beam bending assembly comprising at least one electromagnet configured to adjust a position of the electron beam in the build chamber;

a computer system configured to control the at least one electromagnet;

a build platform configured in a build chamber; and

a powder tank configured to provide the build material to the build chamber.

16. The manufacturing system of claim 13 wherein the conduction cooling system further comprises:

a refrigeration source;

a cavity cooler in conductive contact with the superconducting cavity; and

a cooling connector forming a conductive connection between the cavity cooler and the refrigeration source.

17. The manufacturing system of claim 16 wherein the refrigeration source comprises a cryocooler.

18. A manufacturing apparatus comprising:

a superconducting radio frequency accelerator configured to produce an electron beam;

a refrigeration source comprising a cryocooler;

a cavity cooler for conducting thermal energy away from the superconducting radio frequency accelerator;

a cooling connector forming a conductive connection between the cavity cooler and the refrigeration source;

an electron beam melting assembly comprising:

a beam bending assembly configured to adjust a position of the electron beam; and

a build platform configured to hold a build material, wherein the electron beam melts the build material; and

a flange connecting the electron beam melting system to the super conducting radio frequency accelerator.

19. The additive manufacturing apparatus of claim 18 wherein the superconducting radio frequency accelerator further comprises:

a superconducting cavity;

an electron gun comprising a thermionic cathode, the thermionic cathode being adjacent to a racetrack grid, wherein a cold part of the electron gun is directly exposed to an inside surface of the superconducting cavity, and a flange connected to the thermionic cathode with an Al diamond gasket; and

a power coupler.

20. The additive manufacturing apparatus of claim 18 wherein the superconducting cavity is configured to generate at least a 50 kW beam power at 1 MeV, and a beam current of at least 50 mA in a continuous wave operation.