Copper Additive Manufacturing investigated for optimised synchrotron absorbers
September 19, 2024
The Science Technology Facilities Council’s (STFC) UK Astronomy Technology Centre (UK ATC), Edinburgh, and the UK’s National Synchrotron Diamond Light Source (DLS), Didcot, have collaborated with the University of Wolverhampton, UK, and university research spin-out Additive Analytics, to investigate the use of copper Additive Manufacturing for synchrotron absorbers.
Copper, known for its desired thermal and electrical properties, is critical in numerous applications, especially in the era of net zero, electrified transportation and green manufacturing. However, its laser processing challenges have hindered its widespread adoption in metal Additive Manufacturing technologies such as Laser Beam Powder Bed Fusion (PBF-LB).
The University of Wolverhampton’s Centre for Engineering Innovation and Research (CEIR) and Additive Manufacturing research group have many years of experience in PBF-LB material and process development. In 1999, the university was the first UK institution to install a metal PBF-LB machine.
Utilising the manufacturing freedom offered through its EOS M290 AM machine, the original synchrotron absorber part was redesigned to include conformal cooling channels and gyroid structures for passive cooling and lightweighting. Multiple design adjustments for function and Additive Manufacturing are promising for increased thermal dissipation, reduced material weight and the potential for shorter absorber components.
While further research and testing are still planned for this project, initial prototype simulations show a maximum temperature drop of around 20%, a mass reduction of around 80% and part consolidation from 21 parts to 1. Around 30,000 accelerators and 60 synchrotrons worldwide push the limits of science and could benefit from heritage component redesign using AM.
The thermal performance of the prototypes and associated metrology will be discussed in an upcoming publication.
Professor Arun Arjunan, director of the university’s Elite Centre for Manufacturing Skills (ECMS) and Centre for Engineering Innovation and Research (CEIR) shared, “Working with the STFC, UK ATC and Diamond Light Source optimising their synchrotron absorbers using copper 3D printing techniques highlights the potential of Additive Manufacturing and thermal management. By combining our expertise in advanced materials and 3D printing technologies, we will continue to develop innovative solutions that meet the growing demand for efficient thermal management systems across various industries.”
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