Vacuum electron apparatus has a wide application in civil and military field, such as communication, broadcastings and aviation industry [1][2][3]. An increase of current density cathode at a given working temperature is a main trend in the development of thermionic cathode for different in vacuum devices. Among all the electron emitters, Scandate cathodes have aroused great attention among all the thermionic cathodes due to their high current density [4][5][6].In this paper, scandate doped pressed (SDP) cathodes were prepared by a new method of spray drying combined with two-step hydrogen reduction, instead of traditional mechanical mixing of scandium oxide and barium-calcium aluminates with tungsten. The microstructure, element distribution, and emission properties of the cathodes have been characterized by scanning electron microscope, energy dispersive spectrometer, and an emission test system, respectively.The SEM image of SDP cathode and corresponding EDX results are shown in Fig.l. It can be seen that the cathode prepared by spray drying method have a smooth surface and good sub-micrometer quasi-spherical tungsten grain structure with homogeneous distribution of scandia and barium-calcium aluminates, which are dispersed over and among tungsten grains.The SEM image of cathode cross section and related EDX results [ F ig.2 (a) and (b)] also show that the cathode consists of sub-micrometer quasi-spherical tungsten grains with Sc and barium-calcium aluminate which exist at the interface of the tungsten grains. The sub-micrometer microstructure of cathode is favorable for the active substance diffusing from the inside to the cathode surface and improved the distribution homogeneity of scandia in tungsten Fig.l (a) SEM image of SOP cathode surface and (b) corresponding EOX results Fig.2 (b) SEM image of SOP cathode cross section and (b) corresponding EOX results 978-1-4244-6644-3/10/$26.00 ©2010 IEEE 168