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An oxidation treatment is often performed on austenitic stainless steel prior to joining to alkali barium silicate glass to produce hermetic seals. The thin oxide formed during this pre-oxidation step acts as a transitional layer and a source of Cr and other elements that diffuse into the glass during the subsequent bonding process. Pre-oxidation is performed in a low pO 2 atmosphere to avoid iron oxide formation; the final oxide is composed of Cr 2 O 3 , MnCr 2 O 4 spinel, and SiO 2 . Significant heat-to-heat variations in the oxidation behavior of austenitic stainless steel were observed in this work, resulting in inconsistent glass/metal seal behavior. Twenty-five (25) stainless steel heats were examined including 304L, 316L, and experimental high sulfur alloys similar to 303SS. The objectives were to characterize the oxidation kinetics, the oxide morphologies, and compositions that affect glass/ metal adhesion. It was found that poor glass sealing is associated with a more continuous layer of SiO 2 at the metal/oxide interface. The effects of alloy chemistry, in particular Mn and Si concentrations, on glass/metal sealing behavior were empirically determined. A criterion based on the Mn/Si ratio was developed for use in selecting heats with good glass/metal bonding characteristics. To test this criterion, four other austenitic stainless steels were evaluated: 21-6-9 (also known by original Armco Steel Co. trade name Nitronic Ò 40), 22-13-5 (Nitronic Ò 50), Nitronic Ò 60, and Gall-Tough Ò (Carpenter Technology Corp.). These alloys have compositions significantly different from 300-series alloys, but they were still found to comply with the compositional guidelines developed for predicting glass/metal adhesion.

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In October 2005, an intensive three-year Laser Triggered Gas Switch (LTGS) development program was initiated to investigate and solve observed performance and reliability issues with the LTGS for ZR. The approach taken has been one of mission-focused research: to revisit and reassess the design, to establish a fundamental understanding of LTGS operation and failure modes, and to test evolving operational hypotheses. This effort is aimed toward deploying an initial switch for ZR in 2007, on supporting rolling upgrades to ZR as the technology can be developed, and to prepare with scientific understanding for the even higher voltage switches anticipated needed for future high-yield accelerators.