Method of making a cathode from tungsten and iridium powders using a reaction product from reacting barium peroxide with an excess of tungsten as the impregnant

Claim 2

Method of making a cathode for operation in microwave devices from tungsten and iridium powders using a reaction product formed from reacting barium peroxide with an excess of tungsten as an impregnant, said method including the steps of: (A) mixing the tungsten and iridium 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 1800° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with copper in dry hydrogen at about 1500° C., (G) machining the billet to the desired geometry, (H) removing the copper by etching in nitric acid, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 140° C. for about 15 minutes, (K) impregnating the billet with reaction product formed from reacting barium peroxide with an excess of tungsten 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 iridium powders are mixed in a weight ratio of about 61 weight percent tungsten to about 38 weight percent iridium.

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 according to claim 1 wherein in step (K), the molar ratio of the barium peroxide to the tungsten in the impregnant is less than 3 to 1.

Claim 6

Method of making a cathode according to claim 4 wherein an amount of iridium about the same as the amount of the excess of tungsten is included in the impregnant.

Claim 7

Method of making a cathode for operation in microwave devices from tungsten and iridium powders using a reaction product formed from reacting barium peroxide with an excess of tungsten as an impregnant, said method including the steps of: (A) mixing the tungsten and iridium powders in the weight ratio of about 61 weight percent tungsten to about 38 weight percent iridium, (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 1800° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with copper in dry hydrogen at about 1500° C., (G) machining the billet to the desired geometry, (H) removing the copper by etching in nitric acid, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 1400° C. for about 15 minutes, (K) impregnating the billet with reaction product formed from reacting barium peroxide with an excess of tungsten wherein the molar ratio of the barium peroxide to the tungsten in the impregnant is less than 3 to 1 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 iridium powders using a reaction product formed from reacting barium peroxide with an excess of tungsten as an impregnant, said method including the steps of: (A) mixing the tungsten and iridium powders in the weight ratio of about 61 weight percent tungsten to about 38 weight percent iridium, (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 1800° C. for about thirty minutes in dry hydrogen of less than -100 dewpoint, (F) backfilling the billet with copper in dry hydrogen at about 1500° C., (G) machining the billet to the desired geometry, (H) removing the copper by etching in nitric acid, (I) thoroughly rinsing in deionized water, methanol and then drying, (J) firing the billet in dry hydrogen at about 1400° C. for about 15 minutes, (K) impregnating the billet with reaction product formed from reacting barium peroxide with an excess of tungsten wherein the molar ratio of the barium peroxide to the tungsten in the impregnant is less than 3 to 1 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.