Microwave Component Mechanics -- Contents v -- Acknowledgments xv -- Introduction xvii -- Part 1 Design for Manufacturability and Assembly of Mechanical Microwave Components -- 1 Special Requirements for Microwave Mechanics 3 -- 1.1 Fundamentals of Microwaves 4 -- 1.2 Dimensional Uncertainties 8 -- 1.3 Material Problems 15 -- 1.4 Connection Philosophies 26 -- 1.5 Typical User and Application Profiles 27 -- References 27 -- 2 Systematic Flowchart Model 29 -- 2.1 Principles of Systematic Design 29 -- 2.2 Advanced Methodology for Designing Microwave Mechanics 34 -- References 42 -- 3 Material Selection for Microwave Mechanics 45 -- 3.1 Basic Guidelines for Microwave Designers 45 -- 3.2 Effects of the Product's Operating Frequency 47 -- 3.3 Effects of the Operating Environment 51 -- 3.4 Metallic Components 54 -- 3.5 Use of Plastics 64 -- 3.6 Utilization of Ceramic Materials and Powder Metallugy 66 -- References 77 -- 4 Computer-Aided Environment for Design Work 79 -- 4.1 Integration of Basic CAD Tools 80 -- 4.2 Typical Simulation Software Solutions for Microwaves 96 -- 4.3 Integration Problems of Current CAD Applications 102 -- References 108 -- 5 Instructions for Technical Documentation and Dimensioning 111 -- 5.1 The Relationship Between RF Parameters and Mechanical Parameters 112 -- 5.2 Differences Between DFMA- and Performance-Oriented Approaches 114 -- 5.3 On the Suitability of General Manufacturing Tolerances for MW Mechanics 116 -- References 118 -- 6 Effects of Production Volumn and Related Topics 119 -- 6.1 General Aspects Related to the Evaluation of Production Costs 119 -- 6.2 Relationship Between Manufacturing Costs and Surface Finish 121 -- 6.3 Relationship Between Manufacturing Costs and Dimensional Tolerance 122 -- 6.4 Design for Manufacturability 122 -- 6.5 A Cross-Technological Approach 129 -- 6.6 Concurrent Engineering Design 131.

6.7 Manufacturing Costs of Prototypes 134 -- 6.8 Quality Aspects 135 -- 6.9 Cost Evaluation by Utilizing Parametric Component Design 135 -- 6.10 Cost Accumulation in Laser Processed Components 136 -- 6.11 Manufacturing Costs of Other Manufacturing Processes 141 -- 6.12 A Multilevel Optimizing Approach for Cost-Effective Production 141 -- References 148 -- Part 2 Manufacturing Technologies for Some Passive Microwave Components -- 7 Welded Components 153 -- 7.1 Welding Processes for the Topic Area 153 -- 7.2 Laser Welding in General 154 -- 7.3 Laser-Welded Stripline Filter 157 -- 7.4 Utilizing Ultrasonic Welding in Filter Constructions 164 -- 7.5 Welded Joint Geometries of Microwave Cavity Resonators and Waveguides 170 -- 7.6 Welded Radiating Elements of Patch Antennas 177 -- 7.7 A Comparison of Welding Processes for Encapsulating Electronics 192 -- References 200 -- 8 Other Joining Technologies 203 -- 8.1 Assembly Rules for Screw Joints to Obtain Reliability and Required Microwave Performance 203 -- 8.2 Glued Joints 205 -- 8.3 Applications of Fits 209 -- References 210 -- 9 Machined Components 211 -- 9.1 General Rules for Machining Technologies 211 -- 9.2 Milled Low Loss Filters 215 -- 9.3 Ring Hybrids and Other Milled Power Dividers 218 -- 9.4 General Enclosures for Encapsulating Electronics 224 -- 9.5 Connector Mounting Considerations 229 -- 9.6 Rotary Joints 231 -- 9.7 Case Examples of Precision Machined Microwave Components 237 -- References 240 -- 10 Cutting Processes 243 -- 10.1 Sheet Metal Cutting In General 243 -- 10.2 Water Jet Cut Striplines and Microstrips 246 -- 10.3 Laser Processed Feeding Strips 249 -- 10.4 Tuning Coaxial Transitions 256 -- References 259 -- 11 Forming Processes 261 -- 11.1 Extrusion Processes for Metallic Profiles 261 -- 11.2 Selected Processes for Shaping Plastics 264 -- 11.3 Drawing Processes for Wires 266.

11.4 Forming Processes for Sheet Metals 267 -- 11.5 Electroforming Process for Corrugated Waveguides 268 -- References 269 -- 12 Coating 271 -- 12.1 Basic of Coating Technology 271 -- 12.2 Requirements for Coating Quality 273 -- 12.3 Coating Materials for Microwave Mechanics 273 -- 12.4 Case Examples of Coated Microwave Components 278 -- References 282 -- Part 3 Examples of Requirements for Mechanical Accessories in Microwave Assemblies -- 13 A Microwave Measuring System for Wood Quality 285 -- 13.1 Description of the Test Arrangement 286 -- 13.2 Transducer Arrangements 289 -- 13.3 Mechanical Requirements for the Measurement System Assembly 291 -- References 294 -- 14 Antenna Constructions 295 -- 14.1 Basis for the Design of Antenna Constructions 296 -- 14.2 Wind and Ice Loads 297 -- References 300 -- Part 4 Test Arrangements and Results of Microwave Components Manufactured with Alternative Technologies -- 15 Mechanical Measureing Equipment 303 -- 15.1 Dimensional Uncertainties 303 -- 15.2 Joint Reliability 310 -- 15.3 Surface Properites 310 -- 15.4 Tests for Hermetric Enclosures 317 -- References 318 -- 16 Selecting Microwave Test Instrumentation 321 -- 16.1 Vector Network Analyzers 322 -- 16.2 Spectrum Analyzers 323 -- 16.3 Signal Generators 324 -- 16.4 Cables, Connectors, and Some Accessories 325 -- References 325 -- 17 Examples of Practical Test Set-Ups 327 -- 17.1 Passive Intermodulation in Welded Components 327 -- 17.2 Testing the Shielding Performance of Microwave Enclosures 329 -- 17.3 Experiments on the Input Impedance of Waveguide to Coax Transitions 330 -- 17.4 Analyzing the Effects of Mechanical Defects on the Performance of Small Phased Array Antennas 332 -- References 338 -- 18 Summary 339 -- List of Acronyms 343 -- List of Symbols 349 -- Requirements for Viewing Appendixes A, B, and C 353 -- About the Authors 355 -- Index 357.