Forming superconducting radio frequency cavities using hydrostatically controlled bulging

A method, comprising:

• providing a die assembly having a cavity defined by a first die in contact with a second die, the first die having an opening to receive a metal tube;
• placing the metal tube through the opening of the die assembly such that a portion of the metal tube is in a volume of the cavity;
• disposing an incompressible medium inside of the metal tube through the opening of the first die;
• providing a stepped press ram having a shoulder, wherein there is a gap between an end of the metal tube and the shoulder of the stepped press ram;
• pressurizing only the incompressible medium for a first distance of travel of the stepped press ram into the metal tube;
• and
• contacting the end of the metal tube with the shoulder of the stepped press ram when the gap closes, then pushing axially a second distance of travel of the stepped press ram into the metal tube, thereby forcing metal tube material into the expanding area of the tube wall, and further increasing pressure of the incompressible medium inside of the metal tube.

A method for forming a seamless cavity, comprising:

• providing a die assembly having a cavity defined by a first die in contact with a second die, the die assembly having a single opening, the single opening disposed through the first die to receive a metal tube;
• placing the metal tube through the single opening of the die assembly such that a portion of the metal tube is in a volume of the cavity, the cavity including a space surrounding the metal tube;
• placing a urethane cylinder into the metal tube through the single opening of the first die;
• and
• pressing the urethane cylinder in the metal tube with a single punch or ram positioned at an end of the urethane cylinder, the moving the single punch or ram comprises:
• pressurizing only the urethane cylinder for a first distance of travel of the single punch or ram into the metal tube;
• and
• contacting the end of the metal tube with the single punch or ram and pushing axially a second distance into the metal tube further increasing pressure of the urethane cylinder inside of the metal tube, wherein the urethane cylinder is pressurized inside of the metal tube and a portion of a wall of the metal tube expands into the cavity of the die assembly chamber to form a seamless cavity of the metal tube in the space surrounding the cavity.

A method, comprising:

• providing a die assembly having a cavity defined by a first die in contact with a second die, the first die having an opening to receive a metal tube;
• placing the metal tube through the opening of the die assembly such that a portion of the metal tube is in a volume of the cavity;
• placing a urethane cylinder into the metal tube through the opening of the first die;
• providing a stepped press ram having shoulder, wherein there is a gap between an end of the metal tube and the shoulder of the stepped press ram;
• pressurizing only the urethane cylinder for a first distance of travel of the stepped press ram into the metal tube;
• and
• contacting the end of the metal tube with the shoulder of the stepped press ram when the gap closes, then pushing axially a second distance of travel of the stepped press ram into the metal tube, thereby forcing metal tube material into the expanding area of the tube wall, and further increasing pressure of the urethane cylinder inside of the metal tube.