An Investigation of Production Problems Relating to the Power-Carrying Capacity of a K-Band Microwave Component

Findings are presented on the effect of various mechanical parameters, performance criteria, environmental conditions, and production techniques. Discussion centers about a K-band microwave duplexer, with particular emphasis on the hybrid ring, in an attempt to reduce breakdown rejections. Of humidity, temperature and pressure, only the latter bad a noticable effect on the breakdown measurements. Performance experiments covered pulse width, phasing, rise time and duty cycle with relation to both duplexer breakdown and magnetron life; and with rise time affecting breakdown. The mechanical aspects of dimensions, tolerances, imperfections and finish were investigated; and the latter two found to be the most important. The production techniques contributing to the determined causes were thoroughly investigated. Cleaning processes were proved to be of considerable importance. Corrective measures and effective rework procedures are described.