Manufacturing the LINAC4 PI-Mode Structure Prototype at CERN

The PI-Mode Structure (PIMS) of Linac4 consists of 7cell cavities made from alternating OFE copper discs and rings welded together with electron beam (EB) welding. A full-scale prototype cavity of almost 1.5 m in length has been manufactured, assembled, and tested at CERN to prepare the series production of 12 PIMS cavities as part of an international collaboration. This paper reports on the construction experience including machining operations, EB welding, vacuum brazing, and metrological measurements results.