Failure Analysis Report: 1.0 Problem Reported by Customer

Failure Analysis Report
Date: 17OCT08 Part Description: 5.8 GHz magnetron (used in GA4007A)

By: JF Gerling GAE Part Number: 911405 Rev: 2
Customer: MAUA Serial Number: 392750010
Contact: Jose Senise RMA Number: 1513 Page 1 of 2
1.0 Problem Reported by Customer

From email dated 05-MAY-08: Days ago we noticed that the generator did not sustain for more than a
few minutes a power level of 500W. To-day again, at 500W, with a matched load (reflected power 20 W),
the generator went off again, apparently switched off by the temperature sensor. Notice that air
temperature in the lab was around 17C.
From email dated 08-MAY-08: Comparing with filament of the spare magnetron we bought from you,
shows that indeed filament is open.
No failures of waveguide components were reported.
2.0 Description of Customer Equipment Configuration

None provided other than as indicated above. The microwave generator was delivered along with a
3port circulator (model GA1108) and dummy load (model GA1221) which are typically used in an
isolator configuration to protect the magnetron from reverse power.
3.0 Results of Inspection and Testing

The magnetron filament resistance was measured and found to be infinite, thus indicating an open
circuit. Resistance between the anode and either filament lead was also found to be infinite for both.
Evidence of arcing inside waveguide at the magnetron antenna (photo 1). Vacuum seal broken at
antenna (photo 2). No evidence of arcing along the length of the waveguide.
Photo 1 Photo 2
The magnetron was disassembled and internally inspected. Heavy oxidation was found on the anode
vanes and straps (photos 3 and 4). No deformation of the anode or antenna structures was found.
Photo 3 Photo 4
Failure Analysis Report

Date: 17OCT08 Part Description: 5.8 GHz magnetron (used in GA4007A)
By: JF Gerling GAE Part Number: 911405 Rev: 2
Customer: MAUA Serial Number: 392750010
Contact: Jose Senise RMA Number: 1513 Page 2 of 2
Heavy oxidation was also found on the filament, as well as evidence of the open filament wire (photo 5).
The filament wire is otherwise fully intact and shows no other indication of deformation.
Photo 5 Photo 6
4.0 Analysis and Conclusions

Arcing between the antenna and waveguide can only be caused by an excessively high electric field at
the magnetron antenna. The only possible causes are a high level of reverse power (high VSWR) or an
arc that originated somewhere down the waveguide which would then have traveled to the magnetron
antenna (arcing in waveguide always tends to travel toward the magnetron). Once established between
the antenna and waveguide, arcing would have been sustained as long as microwave power was being
generated.
The sustained arcing eventually caused failure of the vacuum seal between the ceramic antenna body
and metal cap. The sudden inrush of air (oxygen) inside the magnetron body while the filament and
anode were at full operating temperature allowed rapid oxidation of the heated metal surfaces. Since the
filament voltage was still being applied, the filament quickly overheated until melting and thus creating
the open circuit.
Since there is no evidence of arcing along the length of the waveguide, our conclusion is that magnetron
failure occurred due to high reverse power (high VSWR) at the magnetron antenna.
5.0 Recommendations
The microwave generator in which this magnetron was used should never be operated without the use
of a 2-port waveguide isolator (or 3-port circulator and dummy load) to protect the magnetron from
reverse power. Since a circulator and dummy load were delivered along with the generator, it is
presumed these components were installed in a system configuration for magnetron protection as
described in the respective product user manuals that were delivered with the equipment. However, it is
possible that protection may have been compromised if water flow in the dummy load was not provided
according to instructions. The use of a water flow interlock device can help prevent damage due to lack
of water flow.

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Failure Analysis Report: 1.0 Problem Reported by Customer

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Failure Analysis Report

Date: 17OCT08 Part Description: 5.8 GHz magnetron (used in GA4007A)

1.0 Problem Reported by Customer

2.0 Description of Customer Equipment Configuration

3.0 Results of Inspection and Testing

Failure Analysis Report

4.0 Analysis and Conclusions

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