Alternative Manufacturing Meethod for Heaters for Electron Guns by Ink-jet Printing

The proposed method for the fabrication of cathode heaters uses ink-jet printing of solutions containing tungsten particles. This method radically alters the manufacturing approach by introducing a complete data driven technology that will produce consistent heater elements and will allow quick turnaround for design changes.Phase I demonstrated the key elements of the technology: solution formulation; dispensing and printing of the solution onto ceramic substrates; firing of the tungsten particles to form heaters with electrical desired resistance.Phase II will: improve the tungsten particles solutions and ceramic substrates; design and fabricate a mixing printhead; establish the complete fabrication process and design rules for heaters; design and build a pilot line printing system. Heating elements will be fabricated and tested throughout the project to evaluate the materials and to establish the process steps. The established design guidelines and the process will be used to fabricate a test-vehicle heater which will be evaluated for its heating characteristics.In the Phase II option, we will fabricate heaters to be integrated in dispenser cathodes that will be evaluated for performance and reliability. We will also evaluate alternative heater construction, shape and distribution of the heater element within the heater.