SBIR-STTR Award

Describe the problem or situation being addressed. The DOEs and publics interest in the problem should be clearly stated (typically one to three sentences). RF couplers used in all of the superconducting accelerator user facilities consist of a stainless steel base material (for thermal isolation) and a thin Cu film (for RF conductivity). The electro- chemical deposition techniques presently used to apply the Cu to the stainless steel have several draw backs. To encourage adhesion, an unwanted Ni layer is required between the Cu and stainless steel and despite this Cu adhesion is still low. A new technique is needed to produce highly adhered Cu films on stainless steel. Statement of How this Problem or Situation is Being Addressed Describe how this problem or situation is being addressed. The overall objective or approach of the combined Phase I and Phase II projects should be clearly stated (typically one to two sentences). Alameda Applied Sciences Corporation proposes to deposit a Cu thin film onto these stainless steel parts using our patented coaxial energetic deposition (CED) source. Deposition via an energetic source has the potential to create a highly adhered, quality thin film layer because thin film material is actually implanted into the substrate a few atomic layers. In Phase I, Cu films will be deposited on flat stainless steel coupons and tubes to measure the adhesion. In Phase II, a stainless steel coupler will be coated and tested. Commercial Applications and Other

Benefits:
Summarize the future applications and/or public benefits if the project is carried over into Phase II and beyond. Do not repeat information already provided above. Stainless steel coatings are part of a & gt; $150M components market for SRF accelerators. Aside from this, a dense, well-adhered coating on stainless steel has applications in the oil/gas and chemical industry for hard and corrosion-resistant coatings on pipes.

Superconducting radiofrequency accelerators require a critical component that connects the radiofrequency power supply (which is warm) to the accelerator cavity (which is very cold). This coupler component must be insulating on the outside to block heat from going into the cold region. It must also be highly conducting on the inside to minimize radiofrequency power losses. No manufacturer has been able to strike a satisfactory balance. Existing methods do not work well enough to satisfy the requirements of the large new accelerators that need to order thousands of these couplers. AASC has validated a better solution in Ph-I. Alameda Applied Sciences Corporation (AASC) has demonstrated thin films of copper coated onto stainless steel that could meet the conflicting requirements of the RF coupler. Stainless steel blocks heat on the outside while copper conducts RF power efficiently on the inside. Our Ph-I coatings passed a high pressure water rinse test at Fermi Lab. The electrical conductivity of the film is characterized by a parameter called RRR that must exceed 30. Our Ph-I films gave RRR=42-64, in excess of requirements. Commercial Applications and Other

Benefits:
Various governments are expected to invest $1B into superconducting accelerators over the next decade or so. Private sector investment would match or exceed that with breakthroughs as noted above. About 20% of this investment would go to the purchase of RF couplers. This represents a great commercial opportunity. AASC will license its knowhow and patents to larger companies to capitalize on this opportunity.