A radio-frequency quadrupole prototype additively manufactured as a multi-material component

Linear particle accelerators (Linacs) are essential for numerous applications in industry, medicine, and research. However, their use is often constrained by high investment costs, which are largely driven by conventional manufacturing methods. Studies have shown that additive manufacturing (AM) has the potential to significantly reduce these costs while simultaneously enhancing Linac performance. This study investigates this potential for the production of radio-frequency quadrupoles (RFQs), one of the most important Linacs for ion acceleration. For the first time, a multi-material RFQ prototype was fabricated using multi-material (MM) laser powder bed fusion (PBF-LB/M) AM, integrating the copper alloy CuCr1Zr for the internal cavity and tool steel (1.2709) for the outer shell in a single manufacturing step. The prototype’s design features six ConFlat® (CF) flanges for sealing without O-rings, highlighting the advantages of MM AM in simplifying assembly and enhancing functionality. Experimental evaluations included assessments of geometric precision, surface roughness, microstructural integrity, vacuum performance, resonance frequency (f<inf>R</inf>), and quality factor (Q<inf>0</inf>). The results demonstrated the successful application of MM PBF-LB/M for RFQ production, achieving a vacuum pressure below 8.3 ∙ 10^–8 mbar in the prototype. However, challenges in geometric precision and material transition zones necessitate further process optimization. This work underscores the potential of MM PBF-LB/M to address limitations in mono-material AM, particularly for Linac applications. Future developments, such as enabling pure copper processing and improving thermal and mechanical performance, could establish MM PBF-LB/M as a transformative technology for advanced Linac designs, paving the way for enhanced Linac applications.