Intermodulation Product Levels in Flame-sprayed Materials

A preliminary investigation on intermodulation product (IMP) levels of fiberglass-backed flame-sprayed surfaces was completed. The purpose was to demonstrate the use of modified techniques and materials in combustion flame spraying of formed surfaces in reducing intermodulation products. The approach used improved metal wire stock without impurities or with smaller droplet sizes, high-temperature release agents, wire stock with low electrical resistance, variations in spraying distances, and intense buffing processes which amalgamate the material gaps and droplets in an effort to fabricate IMP-free lightweight and low cost subreflectors. Positive material candidates were found with an IMP level around -150 dB, which is comparable to solid aluminum surfaces used as a reference.