Material optimization and application of process controls for "stringer-free" 70/30 copper-nickel and Monel 404 alloys [microwave tube materials]

Summary form only given. Copper nickel alloys (70Cu/30Ni and Monel 404) are integral materials in VED design, chosen during the original development of microwave tube technology to satisfy a complex combination of material property requirements. Historically, the availability of these materials in requisite quality has been cyclic and unreliable. In 2002, a project was launched to establish a long-term, reliable and affordable supply of high-quality copper-nickel alloys to support the continued manufacture of microwave power tubes. The technical approach utilizes a novel casting process to produce material of requisite quality at a lower cost than the incumbent vacuum casting process. An extensive economic analysis was also performed, quantifying the trade-offs between material cost, inspection costs, product yield and economic order quantities. This presentation summarizes the results of this project.