Design and analysis of cooling jacket developed for vacuum power tubes by multiphase cooling

Abstract

Abstract The vacuum tubes are used extensively in electronic industries. The MW level of vacuum tube are used in RF amplifiers and microwave sources in different sectors like defence, nuclear energy, satellites and medical diagnostics. The first step in the indigenous development of MW level of vacuum tube is the design of its cooling jacket. The cooling jacket of vacuum tubes use hypervapotron (HV) fins which are known for providing efficient cooling in compact space. The key objectives of this paper are to finalize the jacket’s construction material, evaluate the cooling jacket’s heat transfer performance at the MW level of RF (radiofrequency) power, and forecast safe operating conditions for given conditions of high heat flux and water flow rates. In this design, the vacuum tubes’ external dimensions are taken into consideration when designing the cooling jacket. ETP copper (Electrolytic Tough Pitch copper) and copper-chromium-zirconium (CuCrZr) are likely materials for the jacket’s construction. For the aforementioned design of the cooling jacket, FEA (Finite Element Analysis) simulations using a steady-state thermal module and computational fluid dynamics (CFD) simulations using an ANSYS CFX module are described for flow rates of 15, 30, and 60 lpm (liters per minute) and the heat flux 1, 2, 4, and 6 MW m−2. The results of CFD and FEA simulations are found to be in close agreement. A small deviation in results is seen after the start of nucleate boiling. 30 and 60 lpm are desirable flow rates for high heat flux values greater than 2 MW m−2. CuCrZr is the ideal material for a cooling jacket’s construction as it has safe working temperature limit of 350 °C at high heat flux values. Also, 15 lpm flow rate should be avoided while using this cooling jacket at heat flux values greater than or equal to 6 MW m−2.