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- Title
Application of hybrid laser powder bed fusion additive manufacturing to microwave radio frequency quarter wave cavity resonators.
- Authors
Riensche, Alex; Carriere, Paul; Smoqi, Ziyad; Menendez, Andrew; Frigola, Pedro; Kutsaev, Sergey; Araujo, Aurora; Matavalam, Nanda Gopal; Rao, Prahalada
- Abstract
In this paper, we present the first known experimental results in using hybrid additive-subtractive laser powder bed fusion (h-LPBF) to make a type of passive radio frequency component called a quarter wave resonator (QWR). The h-LPBF process uses in-situ, interlayer vertical milling to machine certain inaccessible, critical internal features of the QWR device during printing. Using h-LPBF, the as-built surface roughness of functionally important features improved to Ra ~ 2 µm compared to Ra ~ 8 to 20 µm for conventional (additive only) LPBF-processed QWRs. Additionally, the dimensions of certain critical features were closer to their intended design. These metrological improvements resulting from h-LPBF reduced RF losses by a factor of almost 2. Consequently, the RF performance (Q-factor) of h-LPBF-processed QWR components were 1.5 to 2 times superior compared to their conventional LPBF counterparts, and the performance advantage was sustained on stress relief and chemical etching. These results were verified with theoretical electromagnetic simulations.
- Subjects
CAVITY resonators; RADIO frequency; POWDERS; LASERS; SURFACE roughness; BEDS
- Publication
International Journal of Advanced Manufacturing Technology, 2023, Vol 124, Issue 1/2, p619
- ISSN
0268-3768
- Publication type
Article
- DOI
10.1007/s00170-022-10547-y