Microwave tubes used in high-power radar and communications systems are expensive and have an operating life of a few thousand hours. When one fails, it is generally impossible to determine the sequence of events that contributed to its failure. Previous investigators have designed microprocessor-based systems with as many as 11 sensors to monitor tube performance, provide tube protection, and record a comprehensive tube failure history. These systems are limited by the small amount of time available during the tube’s interpulse period for data buffering and fault analysis. They work well if the microwave tube is operated with 200 or fewer pulses per second. However, many tubes are operated at up to 1000 pulses per second. In this effort, an alternative nondestructive testing technique using acoustic emission (AE) was used for in-situ monitoring of normal and abnormal performance of radar tubes, including a magnetron, a klystron, and a traveling wave tube amplifier. This technique captures changes in radio frequency (RF) output pulses due to irregular operation and it is a real-time instantaneous in-situ indicator of the performance of microwave radar tubes. It also offers the possibility of developing built-in prognostic capabilities within the radar system to provide advanced warning of a system malfunction. Understanding the sequence of events leading to a tube failure allows for better maintenance, extends the operating life of the system, and results in significant cost avoidance
