Manufacturing prototypes for LIPAC beam dump

• Electroforming of copper and electronbeam welding techniques are compared.
• Mechanical properties of Cu–stainless steel joint by electroforming are presented.
• Achieved manufacturing tolerances are shown.
• The difficulties and solutions for the complicated manufacturing are explained.

The purpose of the research is to define the most adequate manufacturing process for the dump of a linear deuteron accelerator. The deuteron beam can be pulsed as well as continuous with energies up to 9 MeV. The maximum beam power is 1.12 MW corresponding to a beam current of 125 mA.The requirements on the surface on which the deuterons will be stopped are quite demanding and the length and slenderness of the cone poses a considerable difficulty in the manufacturing process.The design of the beam dump is based on a copper cone 2500 mm long, 300 mm aperture and 5 to 6.5 mm thickness.Basically only two technologies were found feasible for the manufacturing of the cone: Electroforming and Electron Beam Welding (EBW).The article shows the main results found when manufacturing different prototypes.