Optimizing a photon absorber using conformal cooling channels and additive manufacturing in copper
Many of the 70 synchrotron facilities worldwide are undergoing upgrades to their infrastructure to meet a growing demand for increased beam brightness with nanometre-level stability. These upgrades increase the mechanical and thermal challenges faced by beamline components, creating opportunities to...
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| Format: | Article |
| Language: | English |
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International Union of Crystallography
2025-07-01
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| Series: | Journal of Synchrotron Radiation |
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| Online Access: | https://journals.iucr.org/paper?S1600577525003078 |
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| _version_ | 1849430259318915072 |
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| author | Younes Chahid Carolyn Atkins Stephen Hodbod John Robinson Xia Liu Stephen Watson Maia Jones Mark Cliffe Dayo Ogunkanmi Richard Kotlewski Lee Chapman Scott Beamish Jorge Linde Cerezo Thomas Wearing Ahmad Baroutaji Arun Arjunan Chantal Fowler Paul Vivian |
| author_facet | Younes Chahid Carolyn Atkins Stephen Hodbod John Robinson Xia Liu Stephen Watson Maia Jones Mark Cliffe Dayo Ogunkanmi Richard Kotlewski Lee Chapman Scott Beamish Jorge Linde Cerezo Thomas Wearing Ahmad Baroutaji Arun Arjunan Chantal Fowler Paul Vivian |
| author_sort | Younes Chahid |
| collection | DOAJ |
| description | Many of the 70 synchrotron facilities worldwide are undergoing upgrades to their infrastructure to meet a growing demand for increased beam brightness with nanometre-level stability. These upgrades increase the mechanical and thermal challenges faced by beamline components, creating opportunities to apply novel methodologies and manufacturing processes to optimize hardware performance and beam accuracy. Absorbers are important beamline components that rely on water-cooled channels to absorb thermal energy from excess light caused by synchrotron radiation or photon beams created by insertion devices, all within a limited volume, to protect downstream equipment and ensure safe, reliable operation. Additive manufacturing (AM) has been shown to meet criteria relevant to synchrotron environments like leak tightness and vacuum compatibility. However, there is a research gap on the heat transfer and pressure drop impact of different AM conformal cooling channel geometries, as well as the print quality of AM copper parts using low-power infrared lasers and their compliance with absorber requirements. In this study, an intermediate model of a Diamond Light Source photon absorber was optimized to incorporate AM conformal cooling channels, leading to two concept designs named `Horizontal' and `Coil'. When compared with the baseline design, the lightweight Horizontal concept performed the best in this study, with simulations showing a maximum temperature drop of 11%, a calculated pressure drop reduction of 82%, a mass reduction of 86%, and the consolidation of 21 individually brazed pipes into a single manifold. The AM print quality and compliance with the synchrotron environment was examined by producing custom benchmark artefacts and measuring their surface roughness, dimensional accuracy and porosity levels, which are characteristics that can affect heat absorption, structural integrity, thermal conductivity and vacuum performance. The study demonstrates the benefits and addresses outstanding challenges in reducing thermal fatigue, as well as the size, vibrations and energy consumption of AM absorbers. |
| format | Article |
| id | doaj-art-e7cc185fde4d494892dbd32f60f4ab85 |
| institution | Kabale University |
| issn | 1600-5775 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | International Union of Crystallography |
| record_format | Article |
| series | Journal of Synchrotron Radiation |
| spelling | doaj-art-e7cc185fde4d494892dbd32f60f4ab852025-08-20T03:28:04ZengInternational Union of CrystallographyJournal of Synchrotron Radiation1600-57752025-07-0132488489810.1107/S1600577525003078gui5005Optimizing a photon absorber using conformal cooling channels and additive manufacturing in copperYounes Chahid0Carolyn Atkins1Stephen Hodbod2John Robinson3Xia Liu4Stephen Watson5Maia Jones6Mark Cliffe7Dayo Ogunkanmi8Richard Kotlewski9Lee Chapman10Scott Beamish11Jorge Linde Cerezo12Thomas Wearing13Ahmad Baroutaji14Arun Arjunan15Chantal Fowler16Paul Vivian17UK Astronomy Technology Centre, Royal Observatory, Edinburgh EH9 3HJ, United KingdomUK Astronomy Technology Centre, Royal Observatory, Edinburgh EH9 3HJ, United KingdomDiamond Light Source, Didcot OX11 0DE, United KingdomAdditive Manufacturing Functional Materials Research Group, University of Wolverhampton, Telford TF2 9NT, United KingdomDiamond Light Source, Didcot OX11 0DE, United KingdomUK Astronomy Technology Centre, Royal Observatory, Edinburgh EH9 3HJ, United KingdomUK Astronomy Technology Centre, Royal Observatory, Edinburgh EH9 3HJ, United KingdomUK Astronomy Technology Centre, Royal Observatory, Edinburgh EH9 3HJ, United KingdomUK Astronomy Technology Centre, Royal Observatory, Edinburgh EH9 3HJ, United KingdomUK Astronomy Technology Centre, Royal Observatory, Edinburgh EH9 3HJ, United KingdomUK Astronomy Technology Centre, Royal Observatory, Edinburgh EH9 3HJ, United KingdomDiamond Light Source, Didcot OX11 0DE, United KingdomDiamond Light Source, Didcot OX11 0DE, United KingdomDiamond Light Source, Didcot OX11 0DE, United KingdomSchool of Engineering and Innovation, Aston University, Aston Triangle, Birmingham B4 7ET, United KingdomAdditive Manufacturing Functional Materials Research Group, University of Wolverhampton, Telford TF2 9NT, United KingdomESA-RAL Advanced Manufacturing Laboratory, STFC, Harwell Campus, Didcot OX11 0DE, United KingdomDiamond Light Source, Didcot OX11 0DE, United KingdomMany of the 70 synchrotron facilities worldwide are undergoing upgrades to their infrastructure to meet a growing demand for increased beam brightness with nanometre-level stability. These upgrades increase the mechanical and thermal challenges faced by beamline components, creating opportunities to apply novel methodologies and manufacturing processes to optimize hardware performance and beam accuracy. Absorbers are important beamline components that rely on water-cooled channels to absorb thermal energy from excess light caused by synchrotron radiation or photon beams created by insertion devices, all within a limited volume, to protect downstream equipment and ensure safe, reliable operation. Additive manufacturing (AM) has been shown to meet criteria relevant to synchrotron environments like leak tightness and vacuum compatibility. However, there is a research gap on the heat transfer and pressure drop impact of different AM conformal cooling channel geometries, as well as the print quality of AM copper parts using low-power infrared lasers and their compliance with absorber requirements. In this study, an intermediate model of a Diamond Light Source photon absorber was optimized to incorporate AM conformal cooling channels, leading to two concept designs named `Horizontal' and `Coil'. When compared with the baseline design, the lightweight Horizontal concept performed the best in this study, with simulations showing a maximum temperature drop of 11%, a calculated pressure drop reduction of 82%, a mass reduction of 86%, and the consolidation of 21 individually brazed pipes into a single manifold. The AM print quality and compliance with the synchrotron environment was examined by producing custom benchmark artefacts and measuring their surface roughness, dimensional accuracy and porosity levels, which are characteristics that can affect heat absorption, structural integrity, thermal conductivity and vacuum performance. The study demonstrates the benefits and addresses outstanding challenges in reducing thermal fatigue, as well as the size, vibrations and energy consumption of AM absorbers.https://journals.iucr.org/paper?S1600577525003078additive manufacturing3d printingparticle acceleratorheat transferpressure drop |
| spellingShingle | Younes Chahid Carolyn Atkins Stephen Hodbod John Robinson Xia Liu Stephen Watson Maia Jones Mark Cliffe Dayo Ogunkanmi Richard Kotlewski Lee Chapman Scott Beamish Jorge Linde Cerezo Thomas Wearing Ahmad Baroutaji Arun Arjunan Chantal Fowler Paul Vivian Optimizing a photon absorber using conformal cooling channels and additive manufacturing in copper Journal of Synchrotron Radiation additive manufacturing 3d printing particle accelerator heat transfer pressure drop |
| title | Optimizing a photon absorber using conformal cooling channels and additive manufacturing in copper |
| title_full | Optimizing a photon absorber using conformal cooling channels and additive manufacturing in copper |
| title_fullStr | Optimizing a photon absorber using conformal cooling channels and additive manufacturing in copper |
| title_full_unstemmed | Optimizing a photon absorber using conformal cooling channels and additive manufacturing in copper |
| title_short | Optimizing a photon absorber using conformal cooling channels and additive manufacturing in copper |
| title_sort | optimizing a photon absorber using conformal cooling channels and additive manufacturing in copper |
| topic | additive manufacturing 3d printing particle accelerator heat transfer pressure drop |
| url | https://journals.iucr.org/paper?S1600577525003078 |
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