The linear accelerator for the next generation electron-positron linear collider (NLC) will be comprised of nine thousand accelerator struc-tures, each requiring 207 ultra-high precision copper cells. The cost of these nearly two million copper cells is expected to be as much as ten percent of the total cost of the entire machine. In order to reduce the cost of manufacturing these cells, this project will apply adiabatic forming technology to eliminate the rough machining of parts from conventional milling and turning machines. The adiabatic process can mold exotic lightweight metals into shapes not possible with conventional presses, requires little or no lubricants or cutting fluids, and reduces or eliminates cleaning and waste disposal. In Phase I, calculations required to adiabatically form cells were made and a production press was developed, leading prototype parts based upon an actual scaled cell. Metallography and chemistry analyses were performed to document crystal size and uniformity, as well levels and types of chemical residuals introduced during the forming process. In Phase II, a full size press, based upon the operating principles of the smaller press developed and used in Phase I, will be designed, built, tested, and used to produce prototype parts.
Commercial Applications and Other Benefits as described by the awardee: The adiabatic forming process could be the technology of choice for producing the accelerator cells for the NLC. It is extremely fast (milliseconds), reduces or eliminates many manufacturing steps, and uses 80 percent less energy than conventional methods.
