RF Waveguide Adapters

Name: Microwave Waveguide Adapter & RF Signal Interface Couplers – Frigate
Price: 249.00 USD
Availability: InStock

RF Waveguide Adapters are critical when transitioning between waveguide types with differing cross-sectional geometries and propagation modes. Each adapter is designed to maintain modal integrity by suppressing higher-order mode generation and preventing phase distortion. Field distributions are controlled through precise internal profiling, ensuring a clean TE10 to TE11 conversion in complex interconnect topologies.

Material Specification

Copper C101 (ASTM B152), Aluminum 6061-T6 (AMS 4025), Brass C360 (ASTM B16)

Dimensional Tolerances

±0.005mm (Critical Features), ±0.01mm (Waveguide Dimensions), ±0.02° (Flange Angle)

Surface Finish Requirement

Ra ≤0.2µm (Internal), Ra ≤0.4µm (External), Mirror Polish (Optional, Ra ≤0.1µm)

Coating/Plating Specification

Silver Plated (5-10µm, ASTM B700), Gold Plated (1-3µm, MIL-G-45204), Passivated (Optional)

Electrical Conductivity

≥98% IACS (Copper), ≥50% IACS (Aluminum), Skin Depth Optimized for Operating Frequency

Product Description

RF Waveguide Adapters are engineered to provide seamless impedance continuity across dissimilar waveguide systems. Abrupt changes in impedance are mitigated using precision-milled tapers and electromagnetic contour transitions. This reduces reflection coefficients and maximizes power transfer efficiency while protecting sensitive transmitter front-ends from mismatched load conditions.

Certification Standard

ISO 9001, RoHS/REACH Compliant, MIL-STD-202 (Testing), IPC-A-600 (Acceptability)

Waveguide Cutoff Frequency

WR-90 – 6.56-12.5GHz, WR-42 – 18-26.5GHz, Custom Bands Available

Impedance Matching

50Ω Standard, VSWR ≤1.15:1, Return Loss ≥26dB

Flatness & Parallelism

Flatness ≤0.01mm/m, Parallelism ≤0.005mm, Perpendicularity ≤0.01°

Mechanical Strength

Tensile Strength ≥200MPa (Al), Fatigue Life – 10⁶ Cycles, Torque Rating – 2-5Nm (Flange Bolts)

Technical Advantages

RF Waveguide Adapters are designed with tightly controlled voltage standing wave ratio (VSWR) over wide operational frequency bands. Each adapter undergoes full-bandwidth electromagnetic analysis to achieve consistent VSWR targets, typically under 1.1:1. Stable impedance characteristics allow integration into wideband systems without introducing amplitude or phase anomalies.

RF Waveguide Adapters are machined to sub-10-micron tolerance to maintain concentricity and parallelism across the mating planes. Any deviation in alignment at these junctions directly affects S-parameter stability and insertion loss. Dimensional accuracy ensures phase coherence and minimal mechanical stress during assembly and thermal cycling.

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Industry Applications

Satellite Communications Systems

Used to interface rectangular waveguides with circular feedhorns in Ku- and Ka-band transponders for efficient uplink and downlink signal transfer.

Radar Transmitter Modules

Facilitates transitions between high-power TWT amplifier output and waveguide distribution networks while maintaining low insertion loss and phase coherence.

Electronic Warfare Platforms

Supports interconnection of dissimilar waveguide geometries in broadband jamming units requiring wide frequency coverage and minimal reflection coefficients.

Aerospace Payload Integration

Enables waveguide routing between subsystems with differing flange standards under stringent mass, thermal, and vibration constraints in flight hardware assemblies.

5G mmWave Infrastructure

Connects millimeter-wave transceivers to waveguide-based filters and antennas in backhaul and fronthaul links requiring minimal signal dispersion.

Metrology and Calibration Labs

Used in calibration setups to adapt between precision waveguide standards and measurement instruments with traceable low-loss and stable S-parameters.

Thermal Expansion Compensation for High-Power Use

RF Waveguide Adapters used in high-power applications incorporate materials with matched coefficients of thermal expansion (CTE) to maintain structural and electrical performance during prolonged heat exposure. Structural integrity is preserved across waveguide joints, preventing detuning or RF leakage due to thermal drift.

RF Waveguide Adapters used in vacuum, aerospace, or pressure-sealed systems are built with hermetically sealed bodies utilizing laser welding and metal-glass sealing techniques. Leak rates below 10⁻⁸ atm·cc/sec are maintained to meet mission-critical reliability standards. These adapters are compliant with MIL and space-grade hermeticity requirements.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure minimal insertion loss in high-frequency RF Waveguide Adapters?

Frigate uses full-band 3D electromagnetic simulation to optimize the internal geometry of each adapter for minimal conductor and dielectric losses. All critical surfaces are CNC-machined with controlled surface roughness to reduce RF skin-depth attenuation, especially above 40 GHz. Each adapter is tested on a calibrated vector network analyzer for S21 stability. Measured insertion loss values are typically below 0.2 dB across the designated waveguide band.

What methods does Frigate use to prevent mode conversion in complex RF Waveguide transitions?

Frigate designs transitions using smooth, mode-preserving tapers that maintain boundary conditions between differing waveguide profiles. Simulations are performed using full-wave solvers to suppress generation of unwanted higher-order modes, especially near cutoff regions. Internal junctions are aligned within ±0.001” to maintain field symmetry. This approach ensures clean TE-mode propagation across the full operational bandwidth.

How does Frigate handle flange standard mismatches between different RF subsystems?

Frigate manufactures adapters compliant with multiple flange types, including MIL-DTL-3922, UG, and custom configurations. Each RF Waveguide Adapter is designed with precise flange face mating and bolt circle alignment to avoid assembly-induced distortion. Mechanical drawings are generated per customer interface control documents (ICDs) to ensure compatibility. Custom adapter variants are available with asymmetric flange patterns or offset mounting holes as required.

Can Frigate's RF Waveguide Adapters operate under thermal shock or vibration environments?

Frigate selects materials with matched coefficients of thermal expansion and stress-relief features to maintain integrity under thermal shock cycles. Each assembly is mechanically stress-tested for vibrational resonance and joint fatigue across -55°C to +125°C. Flanged joints are reinforced for shear resistance under high dynamic loading. These features support aerospace, defense, and satellite deployment standards.

How does Frigate verify hermeticity in vacuum-compatible RF Waveguide Adapters?

Frigate uses helium mass spectrometry to test hermetic adapters for leak rates better than 1×10⁻⁸ atm·cc/sec, meeting MIL-STD-883 standards. Metal-glass seals or electron-beam welded closures are used to ensure structural sealing under vacuum. Adapters undergo bake-out and residual gas analysis to ensure low outgassing. These practices support cleanroom and orbital payload integration environments.

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Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

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9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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