Application of hybrid laser powder bed fusion additive manufacturing to microwave radio frequency quarter wave cavity resonators
Application of hybrid laser powder bed fusion additive manufacturing to microwave radio frequency quarter wave cavity resonators
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DOI：
10.1007/s00170-022-10547-y
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发表时间：
2022-11
期刊：
影响因子：
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通讯作者：
A. Riensche;P. Carriere;Z. Smoqi;A. Menendez;P. Frigola;S. Kutsaev;Aurora Araujo;N. Matavalam;Prahalada K. Rao
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文献类型：
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作者：
A. Riensche;P. Carriere;Z. Smoqi;A. Menendez;P. Frigola;S. Kutsaev;Aurora Araujo;N. Matavalam;Prahalada K. Rao
在本文中，我们提出了第一个已知的实验结果，使用混合加-减激光粉末床聚变（h-LPBF）制造一种称为四分之一波谐振器（QWR）的无源射频元件。h-LPBF工艺在打印过程中使用原位、层间垂直铣削来加工QWR器件某些不可接近的关键内部特征。使用h-LPBF，与常规（仅添加）lpbf加工的qwr的Ra ~ 8 ~ 20µm相比，功能重要特征的构建表面粗糙度提高到Ra ~ 2µm。此外，某些关键特征的尺寸更接近其预期设计。h-LPBF带来的这些计量改进将射频损耗降低了近2倍。因此，h-LPBF加工的QWR组件的射频性能（q因子）是传统LPBF组件的1.5至2倍，并且在应力消除和化学蚀刻方面保持了性能优势。理论电磁仿真验证了这些结果。
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.