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Multistage depressed collectors (MDCs) play a vital role in efficiency enhancement of traveling-wave tubes for various strategic and communication applications. Design of a highly efficient MDC is no longer a tough challenge due to the availability of large number of efficient numerical simulation tools. However, still an established technique for the development of such MDCs to address their thermal as well as high-voltage breakdown issues has not been published. In this paper, we have exercised different development techniques in the light of specified meritorious aspects with respect to actual dimensional accuracies, thermal dissipation, and high-voltage withstanding capability. We have made use of an analytical method to estimate the proper braze alloy quantity and holding time during brazing operation to ensure optimum brazing, thereby, yielding minimum thermal impedance and improved high-voltage breakdown strength.Index Terms-Analytical model, brazing quality, high-voltage breakdown, multistage depressed collectors (MDCs), thermal dissipation, traveling-wave tube (TWT).

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