Multipactor suppression by micro-structured gold/silver coatings for space applications

The secondary electron emission (SEE) from materials used in high power RF devices in space is the main trigger and sustaining mechanism of the resonant avalanche electron discharge known as the multipactor effect. It limits the attainable power of those devices. During recent decades, some scientific research has been focused on material properties for obtaining anti-multipactor coatings of low secondary emission yield (SEY). The European Space Agency (ESA) is leading a technological research on a new approach based on surface roughness that might perform as a kind of blackbody or Faraday cage effect. A multilayer coating structure was adopted for fulfilling the stringent requirements of the space. The surface of a standard silver plating was modified by a two-step treatment. First, a wet chemically etching process created a roughness of high aspect ratio, in the scale of microns. Secondly, the surface was coated with a protective 2 μm overlayer of gold, using magnetron sputtering. This anti-multipactor coating has been tested on several types of Ku-band WR75 waveguide transformers and band-pass filters, with excellent results. The multipactor effect was suppressed for two waveguides, even when applying the maximum available power levels. As for the other final four, the increase of multipactor power level was in the range of 4-6 dB. These results were obtained after more than one year of air exposure. In spite of the strong roughness, the insertion losses were diminished by 25% with respect to the values attained in the tests of the standard anti-multipactor coating, Alodine.