The cross sectional view of output coupler for M-carcinotron is shown in Fig.2.

We have selected
Alsimag 614, 96% alumina disc of 21.60mm OD, 2mm thickness with 1.80mm diameter through hole at the
centre. Kovar parts are used to make seal of central and outer conductors.
Alumina disc dimensions are achieved through grinding and lapping. Metallization on the desired area
was done by using moly-manganese process Fig.1. Parts are coated using special jigs and masks by brush
techniques. Sintering operation done in H/N atmosphere in belljar furnace at 14500C with slow heating
and cooling rates. After sintering metallized surface is nickel plated to a thin coating of 0.0002 inch
thickness. Now metallized parts are ready to braze with kovar parts to make the desired seal.

Seal Design and fabrication

Sample Cross-sectional view of complete rf coupler and parts are shown in Fig.2. The outer conductor
seal is made by brazing a kovar tube on the curved surface of alumina disc which formed a concentric
joint. Initially the inner conductor kovar pin was brazed in metallized hole later it was modified to make
butt type joint. Two kovar disc of 9.5mm diameter brazed on both face and central kovar pin brazed to
them in the same operation.
This seal withstood all the environmental and heat cycle tests but was not very reliable. Radial cracks
developed either during processing or rf testing. This seal could withstand maximum upto 500W CW rf
power. This design was required to be modified.
At a later stage, the design was modified and Kovar was replaced by Copper. Copper has excellent
vacuum and rf properties, through its mechanical strength is less than that of Kovar. The schematic
diagram of this coupler and its parts is shown in Fig.3. As main problem arise in proper material selection
and fabrication techniques. Alumina disc was replaced by a beryllia disc of ID 9.5mm, OD 21mm and
1.50mm thickness. As shown in the figure both the conductors have been brazed on the curved surface of
the beryllia disc making concentric seal. The large difference of thermal expansion coefficient of copper
and beryllia during brazing is taken care of by making copper part thin at the joint to provide sufficient
yield to copper part. Beside this a helix of thin molybdenum wire of 0.5mm diameter was wrapped
around the outer cylinder, where ceramic-metal bonding was to take place.
Inner conductor made of OFHC copper tube of 9.0mm diameter and 50mm length was annealed in
hydrogen and pushed into beryllia washer. Molybdenum powder of 2-5 micron size was used to fill the
space in between on a vibrator. Brazing was done in hydrogen furnace as usual techniques. This assembly
after leak checking was push fitted in the outer conductor and expansion arrester, 50 turns of a moly wire
of 0.1mm dia. was tightly wrapped around the outer conductor. Pallabraze M.P. 810 0C was used for this
joint. This concentric seal was successfully used for handling 1500 W CW in 1KW klystron tube. This also
qualified the required tests listed in Table I.
Table I Test Results on RF Coupler seals
SI. Test Description Conventional RF Coupler Modified RF Coupler
No.
1 Thermal Cycle 6500C at 100C/min rate. 8000C at 100C/min rate.
2 Thermal Shock -65 C for 15 min to 200 C for 30 -650C for 15 min to 2000C for 30 min.
0 0

3 Acceleration Test
4 Vibration Test
5 Leak Test
6 Mechanical
Strength
7 RF Test
min.
10 g in three mutually 10 g in three mutually perpendicular
perpendicular directions. directions.
5 to 10Hz with 5 mm Peak to Peak, 5 to 10Hz with 5 mm Peak to Peak, 10
10 to 60 Hz with 1 g acceleration to 60 Hz with 1 g acceleration for 50
for 50 min. min.
Leak tight upto sensitivity of 1*10- Leak tight upto sensitivity of 1*10-11
11 torr lit/sec. torr lit/sec.
Stands 60 Kg pulling weight. Stands 110 Kg pulling weight.
Continuously operated at 400 watt Continuously operated at 1.5 KW, CW rf
rf power at 2.6 to 5.4 GHz for 4 hrs power at 1.7 to 2.4 GHz for 10 hours.

Table II Test Results on H.V. Feedthrough seals

SI. Test Description Conventional RF Coupler Modified RF Coupler
No.
1 Thermal Cycle 6500C at 100C/min rate. 8000C at 100C/min rate.
2 Thermal Shock -650C for 15 min to 2000C for 30 -650C for 15 min to 2000C for 30 min.
 min.
3 Acceleration Test 10 g in three mutually 10 g in three mutually perpendicular
perpendicular directions. directions.
4 Vibration Test 5 to 10Hz with 5 mm Peak to Peak, 5 to 10Hz with 5 mm Peak to Peak, 10
10 to 60 Hz with 1 g acceleration to 60 Hz with 1 g acceleration for 50
for 50 min. min.
5 Leak Test Leak tight upto sensitivity of 1*10- Leak tight upto sensitivity of 1*10-11
11 torr lit/sec. torr lit/sec.
6 Mechanical Stands 60 Kg pulling weight. Stands 110 Kg pulling weight.
Strength
7 RF Test Continuously operated at 400 watt Continuously operated at 1.5 KW, CW rf
rf power at 2.6 to 5.4 GHz for 4 hrs power at 1.7 to 2.4 GHz for 10 hours.

2.2 High Voltage Feedthrough seals

This is another important type of seal used to isolate electrodes as well as to withstand high voltages. This
seal has been designed such a way that it meets all the desired parameters. Different types of seals were
made and validated in M-carcinotron and klystron tubes.

Seal Design and fabrication

This seal is different to rf output coupler in respect of thermal loading during operation of the tube. All
alumina-kovar construction has been used for fabrication of this seal, since kovar is the best material to
match Al2O3 in thermal expansion. Concentric as well as butt type joints were designed and tested.
Comparative results are tabulated in Table II.
Multiple pin feed through seal was made for 400W S-band M-carcinotron using 94% alumina tubes of
5.5mm OD 2mm ID and 25mm long metallized on the both sides. Concentric seals were made with kovar
cups as shown in fig. 4. Kovar cups are fitted at both ends and brazed with Au-Cu alloy of M.P.9700C.
Complete feedthrough was made in two brazing operations. This seal was successfully used in 400W S
band M-carcinotron tube and tested upto 15 KV input voltage. Test results Table. II show that mechanical
strength of this seal is very poor. Although it has been reported in literature, that Al2O3 has its
compressive strength 10 times to their tensile strength. But it was observed practically that ceramic
broke just above the brazed joint.
At the next stage the design was modified to butt joint instead of concentric between alumina and kovar
parts. The complete feedthrough and its parts are shown in fig.5. This seal has been tested and used in
1KW CW S band klystron tube, 94% alumina cylinder of 41.2mm OD, 34.80mm ID and 35mm length with
two compensatory rings of 1.80mm thickness were used. Metallization of these parts was done as
described earlier. The complete feedthrough was made in two brazing operation using 850 0C and 9000C
pallabraze alloys. Slow heating and cooling was observed throughout the brazing cycles. All tests listed in
Table. II like thermal cycling, thermal shock, acceleration, vibration, DC, RF and leak were performed. This
seal was mechanically strong by virtue of compensatory butt joint.

3. EVALUATION & RESULTS

Coaxial rf coupler & feedthrough seals are evaluated by comparison method. Tests for a comparison of
quality do not require the precision that is attendant with basic property data. In this paper, therefore, no
attempt is made to generate basic property data. Following tests are carried on to evaluate the seals.
1. Leak test
2. Mechanical strength
3. Mechanical shock & vibration resistance
4. Thermal shock & cycling resistance
5. High Voltage Test
6. RF Test
Prime requirement of all the seals is ultra-high vacuum tightness. Leal testing of all seals is done on
helium leak detector of sensitivity 3*10-11 torr lit/sec. Thermal cycling is performed by subjecting the
joint to 8000C in Hv2 atmosphere at the heating rate of 100C/min and then cooling. Thermal shock
resistance is done by heating the assembly in air to 2000C and quickly immersed into fluid at -650C.
Statistical data are obtained by examining and leak checking each assembly after each cycle.
High voltage feed through is tested by applying high voltage across it. The test is sensitive to surface
cleanliness of the ceramic. Voltage is applied in step of 1 KV up to 15 KV. Coaxial rf couplers are tested for
rf power handling capacity in M-carcinotron and 1KW Klystron tubes. Conventional rf coupler could be
operated upto 500 watts continuous for 5 hours in M-Carcinotron while modified coupler could be
operated upto 1500 W, CW in S-band Klystron amplifier. Failure of coupler was due to excessive heat
generated and stresses developed at the sealing interface. Heat generated by low thermal conductivity
dielectric loss, electrical breakdown, multifactor etc. In the modified coupler OFHC copper and beryllia
used, have higher thermal conductivities and low dielectric constant therefore comparatively better than
conventional coupler. All these test results are summarised in Table-I and Table-II for Rf coupler and feed
through assembly respectively.

3. CONCLUSIONS

Design and development of ceramic-metal seals is a high technology area. In order to make significant
improvements in achieving the best possible performance in any high power microwave tubes, it is
essential to use a reliable ceramic-metal seals. The right design of the joint will compensate the stresses
due to mismatching in thermal expansion of the material used for seal fabrication. For Rf coaxial coupler,
copper is much superior to Kovar. Since thin copper parts are plastic deformer to limit stresses in
ceramic-metal seals. They are better for microwave point of view also. For high voltage feed through
application, compensated butt type seal between Kovar and Alumina provide higher mechanical strength,
easy to fabricate etc. Hence tubes made with the use of these modified seal are most rugged and reliable
and promising.

REFERENCES

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and NAA on the rooting of stem cuttings of mulberry under mist house conditions in
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Air Heater with Longitudinal Fins, Int. Res. J. of Advanced Engineering and Science,
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Cooling Systems with Heat sink, International Journal of Engineering Research And
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Heater Having Corrugated Absorber Plate, International Journal of Emerging
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Beam Technology, International Journal of Science and Research, 6, (9), 913-916.
[18]Kumar Ashwini, Behura A.K., Kumar Ravi and Kumar Amit, 2017. Wire Screen
Matrices Packed Bed Solar Air Heater Performance An Exergetic and Energetic
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[20]Kumar Ashwini, 2017. A review of optimal radial blower design for electronic
cooling system, IAETSD Journal for Advanced Research in Applied Science, 04, (5),
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[21]Kumar Ashwini, 2017. A review report on robotic system for surveillance, IAETSD
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solar air heater performance-A review, Int. Res. J. of Advanced Engineering and
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[23]Kumar, Ashwini, 2017. A review report for heat transfer and fluid flow
Characteristics, global journal of engineering science and research management, 4,
(10), 98-120.
[24]AShwini Kumar, Vipul Ranjan Kaushik, Amit kumar, 2017. A CFD Approach to Show
the Performance of Solar Air Heaters with Corrugated Absorber Plate, IAETSD
Journal for Advanced Research in Applied Science, 04, (6), 46-66.
[25]AShwini Kumar, 2017. Performance of Solar Air Heaters with Corrugated Absorber
Plate- A CFD Approach, International Journal of Innovative Research and Advanced
Studies, 04, (11), 76-86.
[26]Kumar, Ashwini, Prasad BN, Singh KDP, 2018. Development of correlations of heat
transfer and fluid flow characteristics for three sides artificially roughened solar air
heaters, JP Journal of Heat and Mass Transfer, 15, (1), 93-123.
[27]AShwini Kumar, Aruna K Behura, 2018. Investigation for Three Sides Glass Covered
Solar Air Heater with Three Sides Smooth Collector, IAETSD Journal for Advanced
Research in Applied Science, 05, (6), 53-66.
[28]Kumar Ashwini, 2018. Performance Characteristics on CI Engine Using Different
Blends of Chicken Fat Oil, Caster Seed, Cotton Seed Oil, Int. Res. J. of Advanced
Engineering and Science, 03, (3), 205-213.
[29]AShwini Kumar, Jadhav Sanket Sanjay, Rangole Vijay Balasaheb, Pandarkar Rohit
Chandrakant, Patil Shubham Vikas, Thorat Narayan, 2018. Effect Of E/D And P/E
Ratio On Various Parameters In Solar Air Heater Performance, IAETSD Journal For
Advanced Research In Applied Science, 05, (10), 01-08.
[30]AShwini Kumar, 2018. Optimal Thermohydraulic Performance in Three Sides
Artificially Roughened Solar Air Heater, PhD Thesis NIT Jamshedpur.
[31]AShwini Kumar, Jadhav Sanket Sanjay, Haral Ajay Shivaji, Kale Sagar Dattatraya,
Gore Dhanaji
Heater Performance, Int. Res. J. of Advanced Engineering and Science, 03, (4), 67-
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[32]AShwini Kumar, Aruna Kumar Behura, Ravi Kumar 2018. Investigation for the
optimal thermo hydraulic performance in three sides artificially roughened solar air
heaters, Int. Res. J. of Advanced Engineering and Science, 03, (4), 162-172.
[33]Kumar Ashwini, Prasad, B.N and Singh, K.D.P. Performance characteristics of three
sides artificially roughened solar air heaters, Global Conference on Renewable
Energy (GCRE-2016), 04, 132-137, WEENTECH-2016, 4-6 March, 2016, NIT Patna,
India.
[34]Kumar Ashwini, Singh, K.D.P. and Prasad, B.N. Enhancement of collector
performance parameters in three sides artificially roughened solar air heater,
ICASPCT-2016, 17-19 March, 2016, Raigarh, India.
[35]Kumar Ashwini, Behura K Aruna and Kumar Ravi. Performance analysis of three
sided artificially roughened solar air heaters, Applied Science and Advanced
Materials International, 02, 112-116, Second Energy & Materials Science Congress:
ENMAT-II, 2016, OEC Bhubaneswar, India.
[36]Behura K Aruna, Kumar Ashwini, Kumar Ravi and Mishra, S. Heat transfer
enhancement of three sides artificially roughened solar air heater, Applied Science
and Advanced Materials International, 02, 96-100, Second Energy & Materials
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and flow parameters for heat transfer enhancement in artificially roughened solar
air heaters: - A review, Applied Science and Advanced Materials International, 02,
117-123, Second Energy & Materials Science Congress: ENMAT-II, 2016, OEC
Bhubaneswar, India.
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Jaipur, India.
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for Three Sides Artificially Roughened Solar Air Heaters, International Conference
On Advances In Refrigeration & Energy Systems-2018, ICARES-2018/07, 6-7 April
2018, Jaipur, India.
[40] Kumar Ashwini, Lagad Rahul Anil. Feasibility Analysis Of High Altitude Wind Power
System, National Conference On Research As A Motivational Source For A Better
Tomorrow In Making Genius (RMSBTMG-2018), 01-13, 26-27 September 2018,
Kashti, Ahmednagar, India.

[41] Kumar Ashwini, Jadhav Sanket Sanjay. Effect Of Roughness And Flow Parameters
On Solar Air Heater Performance, National Conference On Research As A
Motivational Source For A Better Tomorrow In Making Genius (RMSBTMG-2018),
24-34, 26-27 September 2018, Kashti, Ahmednagar, India.

[42]Anil Tekale, AShwini Kumar, Swapna God. Automatic Fault Detection and Protection
of Three Phase Induction Motor, Lambert Publishing House, ISBN: ISBN 978-613-5-
85178-6, Feb, 2018.
[43]AShwini Kumar, Amit Kumar. Performance Characteristics of Solar Air Heaters by
Using CFD Approach, Scholar's press, European Union, ISBN: ISBN 978-620-2-
31166-3, May, 2018.
[44]AShwini Kumar, Optimal Thermohydraulic Performance in Three Sides Artificially
Roughened Solar Air Heaters, PhD Thesis, NIT Jamshedpur, March, 2018.
[45]AShwini Kumar, Jadhav Sanket Sanjay, Haral Ajay Shivaji, Kale Sagar Dattatraya,

Heater Performance, Int. Res. J. of Advanced Engineering and Science, 03, (4), 67-
72.
 [46]AShwini Kumar, Aruna Kumar Behura, Ravi Kumar 2018. Investigation for the
optimal thermo hydraulic performance in three sides artificially roughened solar air
heaters, Int. Res. J. of Advanced Engineering and Science, 03, (4), 162-172.
[47]AShwini Kumar, Todkari V C, Vipul R Kaushik, 2019. Heat Transfer and Fluid Flow
Characteristics of Three Sides Inclined Roughened Solar Collectors , International
Research Journal of Engineering and Technology, 6 (5), 10-22.

[48]AShwini Kumar, Todkari V C, Vipul R Kaushik, 2019.

Mech
Journal of Emerging Technologies and Innovation Research, 6 (5), 553-560.

[49]AShwini Kumar Optimal Performance Of

Compact Electronic Appliances And Heat Sink Design International Conference on
-
II (ETCDWP-II, 2019) 12-
Jaipur, India.
[50]AShwini Kumar

Virtual Conference on Advances in Design, Manufacturing and Energy

Engineering (VCADMEE-2019), 3rd May 2019, School of Mechanical
Engineering, VIT Vellore, Tamilnadu, India.

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