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Introduction: This study examines how a practical source of X-ray radiation, capable of delivering unprecedented X-ray of 100 Gy/s at 1 m for X-ray FLASH radiotherapy can be designed.Methods: We proposed the design of a linac, capable of accelerating 18 MeV 8 mA electron beam with further conversion to bremsstrahlung X-rays. The design is based on L-band traveling wave accelerating structures with high power efficiency, operating in a short-burst/long-pulse regime that allows operating power supply in a regime, beyond its specifications.Results: This study demonstrates the feasibility of a high-power linac for a clinical X-ray FLASH therapy system, using detailed analysis and simulations. Despite ∼500x higher output than a standard clinical linac, the design utilizes available accelerator components for maximal practicality.Discussion: Recent studies have demonstrated that the FLASH effect that allows to effectively kill tumor cells while sparing normal tissue occurs when large dose rates (≥40 Gy/s) are delivered in less than 1 s. Photons are very attractive since modest energies of several MeV are needed, which can be achieved with compact and cost-efficient accelerators. However, since the efficiency of electron-to-photon conversion is only a few percent, the required beam intensity must be an order of magnitude higher than that state-of-the-art accelerators can provide. The proposed ROAD-FLASH accelerator layout allows achieving both the FLASH dose rate and superior dose conformity, comparing to the similar projects. The current paper focuses on providing a technical roadmap for building an economical and practical linear accelerator for ROAD X-ray FLASH delivery.

The fabrication of high purity copper using additive manufacturing has proven difficult because of oxidation of the powder feedstock. Here, we present work on the hydrogen heat treatment of copper powders for electron beam powder bed fusion (EB-PBF), in order to enable the fabrication of high purity copper components for applications such as accelerator components and vacuum electronic devices. Copper powder with varying initial oxygen contents were hydrogen heat-treated and characterized for their chemistry, morphology, and microstructure. Higher initial oxygen content powders were found to not only reduce surface oxides, but also reduce oxides along the grain boundaries and form trapped H2O vapor inside the particles. The trapped H2O vapor was verified by thermogravimetric analysis (TGA) and residual gas analysis (RGA) while melting. The mechanism of the H2O vapor escaping the particles was determined by in-situ SEM heated stage experiments, where the particles were observed to crack along the grain boundaries. To determine the effect of the EB-PBF processing on the H2O vapor, the thermal simulation and the validation of single melt track width wafers were conducted along with melting single layer discs for chemistry analysis. A high speed video of the EB-PBF melting was performed in order to determine the effect of the trapped H2O vapor on the melt pool. Finally, solid samples were fabricated from hydrogen-treated copper powder, where the final oxygen content measured ~50 wt. ppm, with a minimal residue hydrogen content, indicating the complete removal of trapped H2O vapor from the solid parts.