High-Efficiency, High Average Power Inductive Output Tubes
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Engineering topics
Publications and source records attributed to Ives, Robert Lawrence.
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A new series of MW-class, RF loads were developed that can dissipate power levels exceeding 1.5 MW at frequencies from 28 GHz to 180 GHz. The new loads are designed to reflect less than 0.25% of the input power and operate continuously (CW). Stainless-steel and anodized aluminum versions were developed. The stainless steel version is designed to meet requirements for nuclear facilities, such as ITER, while the aluminum version is capable of power levels exceeding 2 MW CW. The aluminum version is also lighter and less expensive. This report describes the design activities during the program and the performance characteristics of the loads.
Multipactor emission can be a serious issue for vacuum electron devices operating at megawatt power levels. It can lead to catastrophic failure from surface arcs or excessive heating of ceramic windows. Titanium nitride is effective at suppressing multipactor emission; however, sputter coating is not strongly bonded to surfaces and issue related to lifetime have arisen. It’s difficult to ensure a uniform coating over large surfaces. This research investigated atomic layer deposition (ALD) as an improved alternative to sputtered coatings. Test windows were fabricated and coated with TiN using ALD, then tested for RF loss and secondary emission. All ALD samples showed RF loss less than 0.01dB with secondary emission yield equal to or better than reported measurements with sputter coated windows. The program also designed a preliminary ALD system capable of coating windows up to 24 inches in diameter.
This program was tasked with rebuilding an existing gyrotron with a direct ouput coupler. The direct coupler section was built and tested. The program also build an new electron gun and output window. Most subassemblies were completed for a new collector. This report describes the testing and fabrication of components. Unfortunately, issues with the collector assembly depleted funds before the program could be completed. Additional funds will be required to complete the collector and rebuild and test the gyrotron.
This program focused on the development of high-outcoupling efficiency resonators for x-ray free-electron laser oscillators (XFELOs). The goal was to produce a viable design for an XFELO that can be implemented on the LCLS-II which is the x-ray FEL facility under construction at the Stanford Linear Accelerator Center (SLAC). The program designed at regenerative amplifier (RAFEL) design that employs a high-gain undulator with a low-Q resonator with the goal of producing a scientific design for the RAFEL as well as a software suite that can be used to design XFELOs. The Phase I program considered a resonator consisting of six diamond Bragg reflectors/mirrors with two focusing lenses. This resonator was used in conjunction with the electron beam produced by the LCLS-II and the HXR undulator to design a RAFEL producing 3.05 keV photons in the fundamental resonance and 9.15 keV photons in the 3rd harmonic. The research program included the extension of the Optics Propagation Code (OPC) to describe Bragg reflection from diamond crystal mirrors and went on to use OPC, in conjunction with the MINERVA simulation code to treat the undulator interaction, to simulate the RAFEL. Simulations were conducted in both the steady-state and time-dependent regimes to determine the basic performance characteristics of the RAFEL.
This program addressed requirements for photocathodes with high quantum efficiency (QE) and long lifetimes. Currently, photocathodes with QEs above 1% exhibit lifetimes measured in a few hours. This is unacceptable for commercial devices using photocathodes as the electron source. This includes accelerators for industrial, medical, defense, and educational applications as well as emerging applications, such as time resolved electron microscopy. Calabazas Creek Research, Inc. (CCR) and the University of Maryland (UMD) attempted to develop reservoir photocathodes that dramatically increased lifetime and increased the ability to recover from contaminating events, such as loss of system vacuum. The Phase I program demonstrated the viability of the reservoir approach for higher QE cathodes. The Phase II program focused on design, fabrication, and delivery. This included increasing understanding of photocathode physics, investigating design options, addressing performance issues, and developing fabrication and packaging techniques leading to commercial products. The initial task identified specific photocathode materials that provide high QE and are compatible with the reservoir approach. The goal was that these photocathodes be manufacturable in a production environment, understanding that the “environment” is highly specialized. The photocathode geometry was modified to address several photogun performance issues related primarily to emittance. A goal was to reduce or eliminate thermal emittance issues arising from the reservoir heater. The program developed fabrication, handling, and transport techniques and facilities to allow commercial photocathode production for certain materials. Not only was complex chemistry involved, but practical issues of transporting and installing the cathodes into user systems were addressed. A critical goal was demonstration of reservoir photocathodes in operating RF guns, where performance could be directly measured. Success depended on clear demonstration that the cathodes could be produced, delivered, installed, and provide the required performance. The principal effort in this program was to develop reservoir cesium antimonide photocathodes. Cesium antimonide cathodes provide a work function in excess of the 1% goal, while the current generation exhibits lifetimes measured in hours. The reservoir in CCRs’ controlled porosity reservoir (CPR) cathodes provides a mechanism for replacing cesium evaporating from the surface by transporting replacement cesium from the reservoir. This is accomplished by gently heating the reservoir to induce cesium diffusion through micron-scale pores in the reservoir cap and photocathode emitter. Experiments at the UMD determined that cesium diffused from the reservoir would only react with antimony on the surface if the temperature exceeded 300C. At this temperature, however, the surface cesium evaporated faster than it could be replenished from the reservoir. Consequently, the QE decreased each time recessiation was attempted. This appears to be a fundamental problem with this approach. The sections below provide information on accomplishments for each task in the program. Once the issue with cesium antimonide cathodes was identified, CCR refocused the program to begin investigation of graphene coated photocathodes in collaboration with SLAC National Accelerator Laboratory (SLAC). The photocathode test chamber developed in the program was transferred to SLAC for use in the graphene research. This is described below in a task added to the program.
Calabazas Creek Research, Inc. (CCR), in collaboration with Northern Illinois University (NIU), proposed to leverage CCR’s experience in electron beam generation and focusing and NIU’s experience in electron microscopy to develop a 4 MeV UEM with sub-ns temporal resolution and 0.3 nm spatial resolution with a relative energy spread of 10-5. Important design tools for the program were CCR’s 3D, finite element code Beam Optics Analyzer (BOA) and the photocathode design code PHOTOQE. However, early in the program it became clear that information necessary to use PHOTOQE was not available, and the program focused on the modifying to BOA to provide the required functionality.
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The Phase II program developed an internal RF coupler that transforms the whispering gallery RF mode produced in gyrotron cavities to an HE11 waveguide mode propagating in corrugated waveguide. This power is extracted from the vacuum using a broadband, chemical vapor deposited (CVD) diamond, Brewster angle window capable of transmitting more than 1.5 MW CW of RF power over a broad range of frequencies. This coupling system eliminates the Mirror Optical Units now required to externally couple Gaussian output power into corrugated waveguide, significantly reducing system cost and increasing efficiency. The program simulated the performance using a broad range of advanced computer codes to optimize the design. Both a direct coupler and Brewster angle window were built and tested at low and high power. Test results confirmed the performance of both devices and demonstrated they are capable of achieving the required performance for scientific, defense, industrial, and medical applications.
Calabazas Creek Research, Inc. developed a 1.5 MW RF load for the ITER fusion research facility currently under construction in France. This program leveraged technology developed in two previous SBIR programs that successfully developed high power RF loads for fusion research applications. This program specifically focused on modifications required by revised technical performance, materials, and assembly specification for ITER. This program implemented an innovative approach to actively distribute the RF power inside the load to avoid excessive heating or arcing associated with constructive interference. The new design implemented materials and assembly changes required to meet specifications. Critical components were built and successfully tested during the program.
The Phase I activity demonstrated that PhotoQE could be upgraded and modified to allow input using a graphical user interface. Specific calls to platform-dependent (e.g. IMSL) function calls were removed, and Fortran77 components were rewritten for Fortran95 compliance. The subroutines, specifically the common block structures and shared data parameters, were reworked to allow the GUI to update material parameter data, and the system was targeted for desktop personal computer operation. The new structures overcomes the previous rigid and unmodifiable library structures by implementing new, materials library data sets and repositioning the library values to external files. Material data may originate from published literature or experimental measurements. Further optimization and restructuring would allow custom and specific emission models for beam codes that rely on parameterized photoemission algorithms. These would be based on simplified and parametric representations updated and extended from previous versions (e.g., Modified Fowler-Dubridge, Modified Three-Step, etc.).
Development of a Periodic Permanent Magnet (PPM) focused klystron is described. The klystron was designed to produce 10 kW CW at 2.815 GHz. The program developed an innovative PPM circuit that provided extremely uniform magnetic fields at the electron beam location while providing unprecedented access to the RF circuit for tuners and water cooling. Simulations indicated the klystron would produce more than 11 kW with an efficiency exceeding 65%. Problems with the mechanical design prevented successful testing of the initial prototype; however, a new design was successfully developed and implemented in a 6 MW klystron developed in a follow-on program. Funding is being pursued to rebuild the 10 kW RF circuit and complete the klystron development.
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In the Phase I program, Calabazas Creek Research, Inc. (CCR), in collaboration with North Carolina State University (NCSU), fabricated copper accelerator cavities and used Atomic Layer Deposition (ALD) to apply thin metal coatings of tungsten and platinum. It was hypothesized that a tungsten coating would provide a robust surface more resistant to arcing and arc damage. The platinum coating was predicted to reduce processing time by inhibiting oxides that form on copper surfaces soon after machining. Two sets of cavity parts were fabricated. One was coated with 35 nm of tungsten, and the other with approximately 10 nm of platinum. Only the platinum cavity parts could be high power tested during the Phase I program due to schedule and funding constraints. The platinum coated cavity exhibit poor performance when compared with pure copper cavities. Not only did arcing occur at lower power levels, but the processing time was actually longer. There were several issues that contributed to the poor performance. First, machining of the base copper cavity parts failed to achieve the quality and cleanliness standards specified to SLAC National Accelerator Center. Secondly, the ALD facilities were not configured to provide the high levels of cleanliness required. Finally, the nanometer coating applied was likely far too thin to provide the performance required. The coating was ablated or peeled from the surface in regions of high fields. It was concluded that the current ALD process could not provide improved performance over cavities produced at national laboratories using dedicated facilities.
This program explored tailoring of RF pulses used to drive accelerator cavities. Simulations indicated that properly shaping the pulse risetime to match accelerator cavity characteristics reduced reflected power and increased total efficiency. Tailoring the pulse requires a high power, gridded, klystron to shape the risetime while also controlling the beam current. The Phase I program generated a preliminary design of a gridded electron gun for a klystron producing 5-10 MW of RF power. This required design of a segmented cathode using Controlled Porosity Reservoir cathodes to limit power deposition on the grid. The program was successful in computationally designing a gun producing a high quality electron beam with grid control. Additional analysis of pulse tailoring indicated that technique would only be useful for cavity drive pulses that were less than approximately 2-3 times the risetime. Otherwise, the efficiency gained during the risetime of the pulse became insignificant when considering the efficiency over the entire pulse. Consequently, it was determined that a Phase II program would not provide sufficient return to justify the cost. Never the less, other applications for a high power gridded gun are currently being pursued. This klystron, for example, would facilitate development inverse Comptom x-ray sources by providing a high repetition rate (10 -100 kHz) RF source.
This program was tasked with improving the quality and expanding applications for Controlled Porosity Reservoir (CPR) cathodes. Calabazas Creek Research, Inc. (CCR) initially developed CPR cathodes on a DOE-funded SBIR program to improve cathodes for magnetron injection guns. Subsequent funding was received from the Defense Advanced Research Projects Agency. The program developed design requirements for implementation of the technology into high current density cathodes for high frequency applications. During Phase I of this program, CCR was awarded the prestigious 2011 R&D100 award for this technology. Subsequently, the technology was presented at numerous technical conferences. A patent was issued for the technology in 2009. These cathodes are now marketed by Semicon Associates, Inc. in Lexington, KY. They are the world’s largest producer of cathodes for vacuum electron devices. During this program, CCR teamed with Semicon Associates, Inc. and Ron Witherspoon, Inc. to improve the fabrication processes and expand applications for the cathodes. Specific fabrications issues included the quality of the wire winding that provides the basic structure and the sintering to bond the wires into a robust, cohesive structure. The program also developed improved techniques for integrating the resulting material into cathodes for electron guns.