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Advanced Manufacturing

Developing a Novel Longitudinal SRF Cavity to Improve Power and Cost of Compact Accelerators

Company Name: Bailey Tool & Manufacturing
Program Office: Advanced Manufacturing
Location: Lancaster, TX
Email: John Buttles, Owner;
Award Amount: $89,795
Project Term: 12 months
Project Status: Active
Participating Lab(s): Fermi National Accelerator Laboratory


Large particle accelerators, such as Fermi National Accelerator Laboratory's (Fermilab) Tevatron, stretch for miles underground. But scientists and engineers are also developing compact electron accelerators that have a wide variety of potential industry and commercial applications.

Bailey Tool & Manufacturing (BTM) is partnering with Fermilab to develop a new approach for the manufacturing of superconducting cavities for such high-power electron accelerators. The manufacturing method enables superconducting materials to be applied to the cavity by line-of-sight and additive techniques, which provides access to high-temperature superconducting materials not previously used in electron accelerators. The innovation also provides integration with cryogen-free cooling systems, which facilitates flexibility and mobility as well as integration with other components in turn-key commercial systems.

These tools could provide catalytic conversion, manipulation, and treatment at the molecular level in energy and environment markets. Existing thermal or chemical processes can be replaced, either partly or wholly, by accelerators to achieve the same goal at higher efficiency. The cleaving and radicalization actions of high-energy electron irradiation, for instance, provides new opportunities for refining and extracting crude oil. The deep penetration of high-energy electron into gas columns creates opportunities for gas-to-liquid and gas-to-solid conversion, such as the reclamation of flue gas as nitrates for fertilizer or carbonates for cement, and reclamation of methane as liquid fuel. The technology can also bring greater efficiency to wastewater treatment.


BTM is focused on repeatable and reliable forming techniques for resonating cavities, which must also enable the application of superconducting materials as coatings, and must result in a vacuum tight system. These challenges entail questions related to materials, radio-frequency cavity design, and testing under conditions accessible only at Fermilab and other national laboratories. The nature of the company's product facilitates other technology advances that can lead to megawatt-class industrial electron accelerator systems. These systems can increase efficiency and provide unique solutions to municipal wastewater treatment, production of fuels, manufacturing of medical isotopes, treatment of polymeric materials of all kinds, and broadly advance the state of the art in commercial particle accelerator technology.



Expending the commercial footprint for particle accelerators would bolster job creation in the advanced manufacturing field.


Accelerator technology can replace costly and hazardous chemical systems in refining, wastewater treatment, and other industrial applications. Bringing down the cost of accelerator technology will allow innovators to access more of these markets.


Advances in commercial particle physics are useful in a variety of defense applications, including nuclear materials detection and x-ray-based cargo scanning.