Method of making a cathode from tungsten and aluminum powders

Claim 2

Method of making a cathode for operation in microwave devices from tungsten and aluminum powders, said method including the steps of: (A) mixing the tungsten and aluminum powders, (B) adding about 2 percent by weight of an activator to the mixture, (C) ball milling the mixture for about 8 hours, (D) pressing the ball milled mixture into a billet at about 48,000 p.s.i. in a die, (E) sintering the billet at about 700° to 1325° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with methyl methacrylate, (G) machining the billet to the desired geometry, (H) removing the methyl methacrylate by dissolution in acetone, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 700° to 1325° C. for about 15 minutes, (K) impregnating the billet with an impregnant having a melting point less than or equal to 1000° C. by firing the billet in a dry hydrogen furnace at a temperature at which the impregnant melts for about two minutes, (L) removing the billet from the furnace after the furnace is cooled, and (M) removing any loose pieces of impregnant from the billet.

Claim 3

Method of making a cathode according to claim 1 wherein in step (A), the tungsten and aluminum powders are mixed in a weight ratio of about 60 weight percent tungsten to about 39 weight percent aluminum.

Claim 4

Method of making a cathode according to claim 1 wherein in step (B), the activator is about 1 weight percent zirconium hydride.

Claim 5

Method of making a cathode for operation in microwave devices from tungsten and aluminum powders, said method including the steps of: (A) mixing the tungsten and aluminum powders, (B) adding about 2 percent by weight of an activator to the mixture, (C) ball milling the mixture for about 8 hours, (D) pressing the ball milled mixture into a billet at about 48,000 p.s.i. in a die, (E) sintering the billet at about 700° to 1325° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with methyl methacrylate, (G) machining the billet to the desired geometry, (H) removing the methyl methacrylate by dissolution in acetone, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 700° to 1325° C. for about 15 minutes, (K) impregnating the billet with an impregnant having a melting point less than or equal to 1000° C. and selected from the group consisting of barium aluminate, a mixture of barium peroxide with aluminum, and a mixture of barium peroxide with aluminum oxide, by firing the billet in a dry hydrogen furnace at a temperature at which the impregnant melts for about two minutes, (L) removing the billet from the furnace after the furnace is cooled, and (M) removing any loose pieces of impregnant from the billet.

Claim 6

Method of making a cathode for operation in microwave devices from tungsten and aluminum powders, said method including the steps of: (A) mixing the tungsten and aluminum powders, (B) adding about 2 percent by weight of an activator to the mixture, (C) ball milling the mixture for about 8 hours, (D) pressing the ball milled mixture into a billet at about 48,000 p.s.i. in a die, (E) sintering the billet at about 700° to 1325° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with methyl methacrylate, (G) machining the billet to the desired geometry, (H) removing the methyl methacrylate by dissolution in acetone, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 700° to 1325° C. for about 15 minutes, (K) impregnating the billet with an impregnant having a melting point less than or equal to 1000° C. and selected from the group consisting of barium aluminate, a mixture of barium peroxide with aluminum, and a mixture of barium peroxide with aluminum oxide, by firing the billet in a dry hydrogen furnace at a temperature at which the impregnant melts for about two minutes, (L) removing the billet from the furnace after the furnace is cooled, and (M) removing any loose pieces of impregnant from the billet.

Claim 7

Method of making a cathode for operation in microwave devices from tungsten and aluminum powders, said method including the steps of: (A) mixing the tungsten and aluminum powders, (B) adding about 2 percent by weight of an activator to the mixture, (C) ball milling the mixture for about 8 hours, (D) pressing the ball milled mixture into a billet at about 48,000 p.s.i. in a die, (E) sintering the billet at about 700° to 1325° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with methyl methacrylate, (G) machining the billet to the desired geometry, (H) removing the methyl methacrylate by dissolution in acetone, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 700° to 1325° C. for about 15 minutes, (K) impregnating the billet with barium aluminate having a melting point less than or equal to 1000° C. by firing the billet in a dry hydrogen furnace at a temperature at which the impregnant melts for about two minutes, (L) removing the billet from the furnace after the furnace is cooled, and (M) removing any loose pieces of impregnant from the billet.

Claim 8

Method of making a cathode for operation in microwave devices from tungsten and aluminum powders, said method including the steps of: (A) mixing the tungsten and aluminum powders, (B) adding about 2 percent by weight of an activator to the mixture, (C) ball milling the mixture for about 8 hours, (D) pressing the ball milled mixture into a billet at about 48,000 p.s.i. in a die, (E) sintering the billet at about 700° to 1325° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with methyl methacrylate, (G) machining the billet to the desired geometry, (H) removing the methyl methacrylate by dissolution in acetone, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 700° to 1325° C. for about 15 minutes, (K) impregnating the billet with barium aluminate having a melting point less than or equal to 1000° C. by firing the billet in a dry hydrogen furnace at a temperature at which the impregnant melts for about two minutes, (L) removing the billet from the furnace after the furnace is cooled, and (M) removing any loose pieces of impregnant from the billet.

Claim 9

Method of making a cathode for operation in microwave devices from tungsten and aluminum powders, said method including the steps of: (A) mixing the tungsten and aluminum powders, (B) adding about 2 percent by weight of an activator to the mixture, (C) ball milling the mixture for about 8 hours, (D) pressing the ball milled mixture into a billet at about 48,000 p.s.i. in a die, (E) sintering the billet at about 700° to 1325° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with methyl methacrylate, (G) machining the billet to the desired geometry, (H) removing the methyl methacrylate by dissolution in acetone, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 700° to 1325° C. for about 15 minutes, (K) impregnating the billet with a mixture of barium peroxide with aluminum having a melting point less than or equal to 1000° C. by firing the billet in a dry hydrogen furnace at a temperature at which the impregnant melts for about two minutes, (L) removing the billet from the furnace after the furnace is cooled, and (M) removing any loose pieces of impregnant from the billet.

Claim 10

Method of making a cathode for operation in microwave devices from tungsten and aluminum powders, said method including the steps of: (A) mixing the tungsten and aluminum powders, (B) adding about 2 percent by weight of an activator to the mixture, (C) ball milling the mixture for about 8 hours, (D) pressing the ball milled mixture into a billet at about 48,000 p.s.i. in a die, (E) sintering the billet at about 700° to 1325° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with methyl methacrylate, (G) machining the billet to the desired geometry, (H) removing the methyl methacrylate by dissolution in acetone, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 700° to 1325° C. for about 15 minutes, (K) impregnating the billet with a mixture of barium peroxide with aluminum having a melting point less than or equal to 1000° C. by firing the billet in a dry hydrogen furnace at a temperature at which the impregnant melts for about two minutes, (L) removing the billet from the furnace after the furnace is cooled, and (M) removing any loose pieces of impregnant from the billet.

Claim 11

Method of making a cathode for operation in microwave devices from tungsten and aluminum powders, said method including the steps of: (A) mixing the tungsten and aluminum powders, (B) adding about 2 percent by weight of an activator to the mixture, (C) ball milling the mixture for about 8 hours, (D) pressing the ball milled mixture into a billet at about 48,000 p.s.i. in a die, (E) sintering the billet at about 700° to 1325° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with methyl methacrylate, (G) machining the billet to the desired geometry, (H) removing the methyl methacrylate by dissolution in acetone, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 700° to 1325° C. for about 15 minutes, (K) impregnating the billet with a mixture of barium peroxide with aluminum oxide having a melting point less than or equal to 1000° C. by firing the billet in a dry hydrogen furnace at a temperature at which the impregnant melts for about two minutes, (L) removing the billet from the furnace after the furnace is cooled, and (M) removing any loose pieces of impregnant from the billet.

Claim 12

Method of making a cathode for operation in microwave devices from tungsten and aluminum powders, said method including the steps of: (A) mixing the tungsten and aluminum powders, (B) adding about 2 percent by weight of an activator to the mixture, (C) ball milling the mixture for about 8 hours, (D) pressing the ball milled mixture into a billet at about 48,000 p.s.i. in a die, (E) sintering the billet at about 700° to 1325° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with methyl methacrylate, (G) machining the billet to the desired geometry, (H) removing the methyl methacrylate by dissolution in acetone, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 700° to 1325° C. for about 15 minutes, (K) impregnating the billet with a mixture of barium peroxide with aluminum oxide having a melting point less than or equal to 1000° C. by firing the billet in a dry hydrogen furnace at a temperature at which the impregnant melts for about two minutes, (L) removing the billet from the furnace after the furnace is cooled, and (M) removing any loose pieces of impregnant from the billet.

Claim 13

Method of making a cathode for operation in microwave devices from tungsten and aluminum powders said method including the steps of: (A) mixing the tungsten and aluminum powders in the weight ratio of about 60 weight percent tungsten to about 39 weight percent aluminum, (B) adding about 1 percent by weight of zirconium hydride to the mixture, (C) ball milling the mixture for about 8 hours, (D) pressing the ball milled mixture into a billet at about 48,000 p.s.i. in a die, (E) sintering the billet at about 1325° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with methyl methacrylate, (G) machining the billet to the desired geometry, (H) removing the methyl methacrylate by dissolution in acetone, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 1200° C. for about 15 minutes, (K) impregnating the billet with barium aluminate by firing the billet in a dry hydrogen furnace at about 1000° C. for about two minutes, (L) removing the billet from the furnace after the furnace is cooled, and (M) removing any loose pieces of impregnant from the billet.

Claim 14

Method of making a cathode for operation in microwave devices from tungsten and aluminum powders said method including the steps of: (A) mixing the tungsten and aluminum powders in the weight ratio of about 60 weight percent tungsten to about 39 weight percent aluminum, (B) adding about 1 percent by weight of zirconium hydride to the mixture, (C) ball milling the mixture for about 8 hours, (D) pressing the ball milled mixture into a billet at about 48,000 p.s.i. in a die, (E) sintering the billet at about 1325° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with methyl methacrylate, (G) machining the billet to the desired geometry, (H) removing the methyl methacrylate by dissolution in acetone, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 1200° C. for about 15 minutes, (K) impregnating the billet with barium aluminate by firing the billet in a dry hydrogen furnace at about 1000° C. for about two minutes, (L) removing the billet from the furnace after the furnace is cooled, and (M) removing any loose pieces of impregnant from the billet.