CERN’s Large Hadron Collider to be upgraded with tungsten additively manufactured modules

March 30, 2023

The tungsten modules, with around 5000 square holes measuring 1.2 x 1.2 x 150 mm are manufactured using the AMCM M 290-2 FDR Additive Manufacturing machine (Courtesy AMCM/CERN)
The tungsten modules, with around 5000 square holes measuring 1.2 x 1.2 x 150 mm are manufactured using the AMCM M 290-2 FDR Additive Manufacturing machine (Courtesy AMCM/CERN)

The world’s largest and most powerful particle accelerator, the Large Hadron Collider (LHC) based at CERN, is being upgraded with additively manufactured tungsten modules that will enable physicists study rare processes and phenomena with increased precision.

The tungsten modules will form the centre of the LHC’s electromagnetic calorimeter (ECAL), a large 7 x 8 m wall structure that measures the energies of electrons and photons. The ECAL is made up of 12 x 12 cm modules and the plan is to replace the innermost 32 modules, an area of about 0.5 m2 where conditions are most challenging and crucial for success, with the new structures made of tungsten.

THE WORLD OF METAL AM TO YOUR INBOX
Subscribe to our weekly newsletter
Sign up

The tungsten modules are manufactured using the AMCM M 290-2 FDR metal Additive Manufacturing machine from Additive Manufacturing Customized Machines (AMCM), an EOS Group company based in Starnberg, Germany. Each of the tungsten blocks has around 5000 square holes of 1.2 x 1.2 x 150 mm with a 500 µm wall thickness, and are filled with scintillation fibres. The fibres must not be scratched by a rough surface, so the surface quality of the tungsten walls must be high.

The plan is to replace the innermost 32 modules in the ECAL with additively manufactured structures made of tungsten (Courtesy AMCM/CERN)
The plan is to replace the innermost 32 modules in the ECAL with additively manufactured structures made of tungsten (Courtesy AMCM/CERN)

“The production of the new tungsten structures was unthinkable five years ago – 3D printing alone brought the breakthrough,” stated Dipl-Ing Hubert Gerwig, a senior engineer at CERN. “Thanks to the AMCM M 290-2 FDR system with fine detail resolution we get the high-quality parts we need for this experimental setup, which is very sensitive to the smallest imperfections.”

The AMCM M 290-2 FDR is a dual head fine detail resolution Laser Beam Powder Bed Fusion (PBF-LB) Additive Manufacturing machine and is suited to demanding applications such as this. It has two 400-watt lasers and a build volume of 150 x 220 x 325 mm.

cms.cern

amcm.com

Download Metal AM magazine

About Metal Additive Manufacturing magazine

Metal AM magazine, published quarterly in digital and print formats, is read by a rapidly expanding international audience.

Our audience includes component manufacturers, end-users, materials and equipment suppliers, analysts, researchers and more.

In addition to providing extensive industry news coverage, Metal AM magazine is known for exclusive, in-depth articles and technical reports.

Our focus is the entire metal AM process from design to application.

Each issue is available as an easy-to-navigate digital edition and a high-quality print publication.

In the latest issue of Metal AM magazine

Download PDF
 

Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

  • Metal powders in Additive Manufacturing: An exploration of sustainable production, usage and recycling
  • Inside Wayland Additive: How innovation in electron beam PBF is opening new markets for AM
  • An end-to-end production case study: Leveraging data-driven machine learning and autonomous process control in AM
  • Consolidation, competition, and the cost of certification: Insight from New York’s AM Strategies 2024
  • Scandium’s impact on the Additive Manufacturing of aluminium alloys
  • AM for medical implants: An analysis of the impact of powder reuse in Powder Bed Fusion

The world of metal AM to your inbox

Don't miss any new issue of Metal AM magazine, and get the latest industry news. Sign up to our twice weekly newsletter.

Sign up

Looking for AM machines, metal powders or part manufacturing services?

Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

  • AM machines
  • Process monitoring & calibration
  • Heat treatment & sintering
  • HIP systems & services
  • Pre- & post-processing technology
  • Powders, powder production and analysis
  • Part manufacturers
  • Consulting, training & market data
View online

Discover our magazine archive…

The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

  • Reports on visits to leading metal AM part manufacturers and industry suppliers
  • Articles on technology and application trends
  • Information on materials developments
  • Reviews of key technical presentations from the international conference circuit
  • International industry news

All past issues are available to download as free PDFs or view in your browser.

Browse the archive

Share via
Copy link
Powered by Social Snap