Precision-machined copper split-section accelerator structures

Electron beam accelerators

Split-section X-band structures.

A high-performance accelerator architecture built from two precision-aligned monoblock sections with distributed RF coupling and integrated thermal management.

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Distributed couplingElastic averagingMonoblock construction

Architecture

Precision through a simpler structure.

The Dymenso split-section accelerator divides the RF structure into two monoblock halves. Precision alignment features register the sections through elastic averaging, while distributed coupling delivers RF power along the structure.

Two sectionsMonoblock split construction
Micron-levelSection-to-section alignment
Lower part countCompared with conventional structures

Design logic

The alignment is built into the interface.

Rather than locating many individual cells, the architecture uses precision features across two monoblock sections to establish the accelerator geometry.

Cutaway schematic of the split-section accelerator showing cells, vacuum joint, monoblocks, and precision alignment pins
01 / ALIGN

Elastic-averaging interface

Multiple precision features work together to align the two sections at the assembly interface.

02 / COUPLE

Distributed RF coupling

Power is coupled along the accelerator rather than through a single conventional input path.

03 / ASSEMBLE

Reduced part count

Monoblock halves consolidate cell geometry and simplify the physical structure.

CFD temperature and coolant-flow simulation of the split-section accelerator
Thermal-fluid simulation of the internal cooling network.

Thermal performance

Cooling follows the heat.

Monoblock sections allow cooling channels to be routed around high-heat-flux regions. This improves heat removal, limits vacuum-wall thermal stress, and supports higher-power operation.

Built hardware

From precision surfaces to the joined assembly.

The architecture supports multiple joining approaches, including electron-beam welding for structures made from hard copper alloy.

Completed copper X-band accelerator assembly with RF input flange
X-band accelerator assemblyAssembled split-section accelerator structure.
Hard copper-alloy accelerator structure joined by electron-beam welding
Electron-beam welded structureHard copper-alloy construction for high-gradient operation.

Technical publication

Read the development work.

Journal of Physics: Conference Series

Fabrication of Split-Section X-band Structure Using Elastic Averaging

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