Laser powder bed fusion for x-band RF cavities: A preliminary study

With increasing operational frequency ($f_R$), the size, weight, and power consumption of linear accelerators (Linacs) decrease, which is why e.g. X-band LinVarious studies show that additive manufacturing (AM) has the potential to significantly reduce the cost of radio frequency cavities (cavities) while increasing performance. With increasing resonance frequency, the size, weight, and power consumption of linear accelerators (Linacs) decrease, which is why, e.g. X-Band Linacs are attractive for industry, medicine, and science. This work investigates, for the first time, whether laser powder bed fusion (PBF-LB/M) offers the geometric accuracy necessary for X-Band cavity manufacturing. Eight 9.29 GHz side-coupled test cavities, each comprising three single cells, were fabricated from CuCr1Zr. One of the cavities was post-processed using plasma electrolytic polishing to increase the quality factor. The manufactured cavities were evaluated using a Vector Network Analyze and an optical 3D profiler.