19 Gennaio 2016 – ASI, Roma.

Primo Workshop Nazionale su “La Componentistica Naz ionale per lo Spazio: Stato dell’arte, Sviluppi e Prospettive"

Klystron e TWT dalla banda L alla banda Wper payload spaziali - E ‐‐‐‐gun e Catodi per electric propulsion

R. Martorana, A. Spatola, P. Arpesi

Table of Contents

Palermo Plant – TWT & Microelectronics• History• Technology• Highlights• Heritage and Trend• Product and Technology Roadmap

Space Activities• Feasibility study on pulsed Klystron for Ka-band SAR instruments• C-band Klystron Breadboard for MetOp SG SCA• Cathodes for Neutralizers

Palermo Plant – TWT & Microelectronics

• History• Technology• Highlights• Heritage and Trend• Product and Technology Roadmap

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• 1956 The Palermo Plant was established by ELSI.• 1960 Raytheon-ELSI was founded as ELSI merged with Raytheon for the production of

vacuum electronic devices and microwave tubes (magnetrons and klystrons).• 1975 the core business of the Palermo Plant became the design and manufacturing of

high power microwave tubes such as High Power Coupled Cavity TWT’s for Tornado,etc….

• 1992 ALELCO S.p.A . was formed from the merging of the Microwave Tube Divisions ofElettronica S.p.A . (Helix TWT’s) and Alenia S.p.A . (Coupled Cavity TWT’s).Microelectronic business is introduced.

• 2003 the assets of ALELCO have been assigned to the new company Galileo AvionicaS.p.A

• 2009 Galileo Avionica and Selex Sensors & Airborne Systems merged into thetransnational company Selex Galileo .

• 2010 the Palermo site has been organized as a Centre of Excellence for satisfying ourCustomer and being their partner for Microwave Power and Integrated Receiver andExciter Solutions for Radar, Security, EW&ESM Systems.

• 2013. Palermo site maintain his structure with the new Selex ES company.• 2016. Finmeccanica “One Company”.

History

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TWT Technologies and Capabilities

Key high power vacuum device technology includes: vacuumexpertise including brazing, RF induced and resistance welding;etching and plating; manual and automated microwave high powerCW and pulsed testing; facilities for inspection, including CNCcontactless equipment and SEM electronic microscope.

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Total land: 16,000 sq meters

Production area:5,000 sq meters

Class 10.000 clean rooms:TWT clean rooms400 sq meters

Microelectronics 600 sq meters

Palermo Plant - Highlights

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Heritage

Tx in the Aster missile seeker-1000 TWTs produced since the 2003

Combat radar for Tornado-1800 TWTs produced since the 80s

Captor for EF Typhoon-500 TWTs produced since the ‘94

ET980 – CC TWT ET963 – CC TWT ET5515 – mini TWT

ET6404 – Helix TWT Helix TWT & Microelectronics for

SCP01 Radar

Helix TWT & Microelectronics for

Grifo Radar

1000 TWT produced since the ‘95

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New Products

Wide band

Front End

Mini TWT and MPM for

EW, UAV, Comms,

Radar

Solid State

Power

Amplifiers

RF and uW Hybrids

Space Tubes and

Hybrids

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2015 20162013 2014

Vacuum Devices - Products and Technology RoadmapD

ecre

asin

g T

RL

–In

crea

sing

res

earc

h ef

fort

TRL 1-2

TRL 3-4

TRL 7-8-9

Space Tubes

MPM

TWT

Mini TWTs 6666----18 GHz 18 GHz 18 GHz 18 GHz 150W150W150W150W

9999----10 GHz 10 GHz 10 GHz 10 GHz 1.5kW1.5kW1.5kW1.5kW

High efficiency SWS

Millimeter SWS

4444,,,,5555----18181818GHz GHz GHz GHz 125125125125WWWW

32 32 32 32 ---- 38 38 38 38 GHzGHzGHzGHz 100W100W100W100W

26262626----40404040GHz GHz GHz GHz 111100000000WWWW

2017

Anodeless elctron guns

Space qual cathodes

6666----18 18 18 18 GHz GHz GHz GHz 150150150150WWWW

4444,,,,5555----18181818GHz GHz GHz GHz 125125125125WWWW

9999----10 10 10 10 GHz GHz GHz GHz 1.51.51.51.5kWkWkWkW

26262626----40GHz 40GHz 40GHz 40GHz 111100W00W00W00W

C band EBB C band EBB C band EBB C band EBB KlystronKlystronKlystronKlystron

FullyFullyFullyFully qualifiedqualifiedqualifiedqualifiedproduction lineproduction lineproduction lineproduction line

2018

32 32 32 32 ---- 38 38 38 38 GHzGHzGHzGHz 100W100W100W100W

18181818----40404040GHz GHz GHz GHz 111100000000WWWW

18181818----40404040GHz GHz GHz GHz 111100000000WWWW

X band and Ku band X band and Ku band X band and Ku band X band and Ku band for SAR / EOSfor SAR / EOSfor SAR / EOSfor SAR / EOS

TRL 5-6

Large CC Tubes

9999----10 GHz 10 GHz 10 GHz 10 GHz 12kW 10%12kW 10%12kW 10%12kW 10%

C band C band C band C band 60kW 5% 60kW 5% 60kW 5% 60kW 5% PPMPPMPPMPPM

C band C band C band C band 25kW CW 25kW CW 25kW CW 25kW CW KlystronKlystronKlystronKlystron

Ka Band Klystron Ka Band Klystron Ka Band Klystron Ka Band Klystron feasbilityfeasbilityfeasbilityfeasbility studystudystudystudy

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Space Activities

• Feasibility study on pulsed Klystron for Ka-band SAR instruments

• C-band Klystron Breadboard for MetOp SG SCA

• Cathodes for Neutralizers

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Activities for Space

Finmeccanica TWT capabilities can be successfully exploited for theSpace business. For this reason in the last four years severalventures have been undertaken also with the support of the ESAand Airbus.

• Feasibility study on pulsed Klystron for Ka-band SAR Instruments• C-band Klystron Breadboard for MetOp SG SCA• Cathodes for Neutralizers

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Feasibility Study on pulsed Klystron for Ka-band SAR Instruments

Supported by ESA

13© 2014 Finmeccanica Ltd – All rights reserved

Ka-band Klystron – the Feasibility Study

Parameter Unit Range/Limit

Operating Frequency Range GHz 35.75

Operating Bandwidth MHz ≥350

Transmitted Peak Power W 3500

Duty Cycle % 13

In Orbit lifetime ≥ 5 years

An ESA internal study on the feasibility of a Ka-band SAR instrument and interferometerhas pointed to the need of a Ka-band High Power Amplifier (HPA) with capabilitiesbeyond what is currently available on the market.

ESA is currently investigating with Industry the feasibility of Ka-band SAR missions forwhich a pulsed Ka-band High Power Amplifier is required.

Within this framework and contracted by ESA, Finmeccanica TWT team has successfullycompleted a feasibility study for a High power HPA inclusive of the vacuum tube with thecharacteristics summarized in the following table.

14© 2014 Finmeccanica Ltd – All rights reserved

Ka-band Klystron – Conclusions

The Feasibility Study has shown that the vacuum tube technology can achieve therequired performance in terms of peak power and bandwidth but, currently, no existingspace qualified EIK is available, achieving the challenging Ka-band SAR requirements

no technological showstopper prevent the developme nt of a new Ka band pulsed vacuum tube.

the development of a new vacuum tube is needed in o rder to develop a space high power amplifier for this application.

Moreover, since no European product is available for the purpose, either space oravionic/ground, export restrictions may be an issue,

the opportunity to develop a fully European device for such application has been looked at, as a further object ive .

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C-band Klystron Breadboard for MetOp SG SCA andCathode life test

Supported by ESA / Airbus

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C-band Klystron – Introduction

• Radar based instruments are essential for Earth Observation purposes.

• The key issue relevant to the EO Radars is the availability of vacuum tube amplifiersdelivering several kW output power.

• A pre-development of a C-band klystron is presently running at Finmeccanica inPalermo, Italy, focused on the MetOp Second Generation Scatterometer, under ESAcontract, aiming to an all-European device .

• Main characteristics and design requirements:1. Carrier frequency 5.3 GHz2. Peak Power 2 kW ÷ 3 kW3. Duty cycle 1% ÷ 7%

• The development plan includes a cathode life test for the verification of the extended lifetime requirements.

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C-band Klystron – Design and Development (1/2)

• The running development is grounded on the Finmeccanica space projects heritage and

production tubes line established in 1950 with technologies well proven in the militaryenvironment.

• Objective = TRL 5

• Klystron Breadboard (BB) has been completed to demonstrate the RF peak performancesverification at low duty cycle, an EBB (Elegant BB) will follow (Q1-2016) for electricalperformances verification at full duty cycle and over qualification temperature range.

• The BB constructional features are representative of the flight model for the: Electron gun,the RF structure and the Magnetic focusing structure.

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C-band Klystron – Design and Development (2/2)

• An EBB (Elegant BB) Model designed for electrical performances verification at full duty cycle and over qualification temperature range shall be finalized by the first quarter 2016.

SYMB. PARAMETER LIMIT-VALUES

UNITS MEASURES MIN MAX

F Operating Frequency 5354 5356 MHz 5355

DC Duty Cycle 1% 1% 1%

Po Peak Output Power 2.2 2.8 kW 3.334

ΔPo Output Power Variation over

frequency range

--- 0.2 dB 0.2

HOR Harmonics (up to 5th) --- -20 dBc -20

S Spurious --- -50 dBc -50

PW Pulse Length 1.15 1.15 msec 0.575

PRF Pulse Repetition Frequency 8.7 8.7 Hz 8.7

Pin RF input power 28 34 dBm 29.3

VSWR Source and Load VSWR --- 1.25:1 1.25:1

ηe Electronic efficiency 30% --- 32.6%

ηtot Tube efficiency 40% --- 41%

• The vacuum tube has been manufactured, assembled and tested and the results haveconfirmed that the Finmeccanica technology meets the RF performance at low dutycycle. A multipactor analysis has been carried out resulting in more than 8 dB margin.

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C-band Klystron – The Way forward to Space

• In February 2016 the EBB shall be finalized. Should the METOP SG SCA be continued based on the Finmeccanica Klystron solution a set of EMs shall be implemented

• Purpose of the EMs will be to demonstrate the required RF and electrical performances in the space environment, see the table. The EMs (3 off) will be representative in Form, Fit, and Functions of the flight klystron and made with commercial parts

TEST EM1 EM2 EM3Dimensional X X XElectrical X X XVibration XMechanical Shock XHot/Cold temperature X XThermal Vacuum X Temperature mapping (operating) XTemperature mapping (overduty) XExternal discharges (corona) XLife Test X

Deliverable METOP SCA Phase

Master Plan

EM * B2 03/02/2017 EQM C 16/11/2017 PFM/FM1 D 26/07/2018 FM2 D 10/01/2019 FM3 D 27/06/2019 FM4 D 12/12/2019 FM5 D 28/05/2020 FM6 D 12/11/2020 FM spare D 29/04/2021

• The EQM, PFM and Flight Models of the program shall follow as summarized in the table herein after.

• A cathode life test is being implemented inorder to demonstrate that proprietaryFinmeccanica cathode technology is suitablefor Space operational requirement.

20© 2014 Finmeccanica Ltd – All rights reserved

Cathode Life Test and the C-band Klystron

• The Cathode life test is a program running at Finmeccanica Palermo premises underAirbus/ESA contract, with the purpose to demonstrate the accelerated life test and thatFinmeccanica cathode technology is suitable for the space application and to verify the lifeof the cathode that will be assembled on the klystron for the application in the MetOpinstrument.

• The activities comprise the manufacturing 7 diodes, named Life Test Vehicles (LTV)employing the expected cathode geometry designed for the Klystron and operated at therequired current density.

• The LTV’s performance will be assessed for different cathode temperatures that will be set at the beginning of life:

• 3 LTV’s will be tested at nominal cathode temperature• 2 LTV’s at 40°C more than the nominal temperature• 2 LTV’s at 80°C more than the nominal temperature

• All the LTV’s will be ran with “heater on” only.

• On monthly basis their performance will be recorded.

21© 2014 Finmeccanica Ltd – All rights reserved

Cathode Life Test Status

• LTVs began the test in October.• By April 2016 the first results will demonstrate the expected life (as a first evaluation)• Every six months further improved predictions will be available. • The test will be completed by July 2017 and will demonstrate the accelerated life of 7.5

years mission requirement for the MetOp SG

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C-band Klystron – Conclusions

• Radar based instruments are essential for Earth Observation purposes, availability ofvacuum tube amplifiers delivering kW output power is a key issue relevant to the Radar.

• A C-band klystron for the Windscatterometer Instrument for MetOp Second Generation isunder development at Finmeccanica, under ESA contract.

• A representative Breadboard (BB) has been completed and the electrical test resultshave shown excellent results, demonstrating that the design and technology selectedand available in Finmeccanica can meet the required performances.

Way forward…• The development plan includes a cathode life test, currently running, for the verification

of the extended lifetime requirements.• The present development will be shortly completed with an EBB, fully representative of

the flight model. This will allow to achieve a TRL 5.• Should the METOP SG SCA be continued based on the Finmeccanica Klystron solution

a set of EMs shall be implemented to be available in 1 year. Purpose of the EMs will beto demonstrate the required RF and electrical performances in the space environment.

• The EQM shall be available by the Q4’17 and the PFM by the Q3’18 in accordance tothe METOP program master plan currently available.

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Cathodes for Neutralizers

Self funded

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CATHODES Technologies

• The cathode technology available at Finmeccanica and presently being qualified forSpace operation has been implemented for application as E-gun in the Electron tubesbut this asset can be also exploited for providing Electric Propulsion (EP) systems withCathode / Neutralizer.

• The EP is becoming a key solution for the management of the orbit for LEO/GEOpayloads especially if mini and micro satellite are considered and with respect toconventional propulsion systems.

• The Cathode/Neutralizer is a “key” component of an Electric Propulsion (EP) System,and can significantly affect the performances and reliability of the whole EP system.

• Finmeccanica, Florence team, has accumulated a remarkable heritage on the IonThruster installed on ARTEMIS satellite using cathode procured from the US, the futuredevelopments in the field are based on the proprietary cathode developed in the Palermoplant.

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Conclusions

Finmeccanica Vacuum Tubes capabilities are being successfully exploited in the Space field and several new developments are foreseen.

• The C-band Klystron for MetOp SG SCA phase B and C development and supply of the items for the flight units.• The Cathode life test is running in order to demonstrate 7.5 years

operating life for satisfying the MetOp SG requirements.• Development of pulsed Klystron for Ka-band SAR instruments that the

ESA is going to implement in the near term.• Cathodes for Neutralizers for the ESA programs and other foreign

entities.

Other opportunities might include the “space upgrading” of existing Helix TWTs for:- L / C / X band SAR Earth Observation systems for LEO satellites;- Ku / Ka / W band for communication satellites;

To be intended for different applications by several Countries.

THANK YOU FOR YOUR ATTENTION

Pier Giorgio ArpesiTime & Frequency - Space Platforms & Robotics - Airborne and Space Systems Division piergiorgio.arpesi@finmeccanica.comAntonio SpatolaSales – TWT & Microwave – Airborne and Space Systems Division antonio.spatola@finmeccanica.com(mob.) +39 3357147793 (tel.) +39 0916482949Via Villagrazia 79, – Palermo – 90125 – Italy