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Process development and concept testing applying additive manufacturing and additional technologies to the fabrication of innovative and functional solutions applied to ultra-high vacuum lines in the context of the Sirius challenge

Abstract

Ultra-high vacuum lines are typical in high-energy subatomic particle accelerators, like the one of Sirius class of the LNLS (Sincrotron Light National Laboratory), and have demands for devices capable to work under vacuum conditions around 50 picobar, 210 degree C temperature, among others. Despite their high technology, today manufacturing techniques are based on subtractive approach, what limitates mainly high complexity geometry achievement and multiple material combinement. With that in mind, attending to the Sirius challenge, the objective of this proposal is to apply Additive Manufacturing (AM) technologies based on metallic and ceramic materials, enabling development of solutions with complex geometries and exclusive characteristics, specially developed to fit the working specifications of ultra-high vacuum lines. The methodology for such development will include the use of metal-based AM technologies working with laser and electron beam, in order to obtain parts that fit the specifications. Besides, it will be considered additional machining process for post-processing the parts to achieve demanded specifications, like surface finishing and dimensional quality, which are impossible to have only using MA. Beyond, it will be studied MA technologies for ceramic materials, capable to produce pre-pressed shaped ceramics, with high complex geometries, capable to fit the operational conditions of ultra-high vacuum lines. The resulting products will be metallic, first in stainless steel (316), CrCoW alloy and Ti6AI4V, as well as aluminum and zirconium oxide based ceramics. Besides, post-processing of the AM parts, in order to achieve surface finishing and dimensional precision will be done. Based on these results, it is expected a revolution in the design of the devices for ultra-high vacuum lines and similar applications, unleashing the creative capability of the developers for innovative and optimized solutions, provided there will be no more geometric complexity limitations. Applications as aerospace; deep water; microfluidic devices and advanced devices will benefit from the developments of this proposal. (AU)