| Summary: | <inline-formula> <tex-math notation="LaTeX">$30~\mu $ </tex-math></inline-formula>m ultra-thin Mo-Re sheet had been joined by micro resistance spot welding (MRSW) and successfully applied to the low heating power cathode of traveling wave tube (TWT). The effects of different welding parameters, surface state and protection conditions on the joint’s appearance, micro-structure and lap shear strength (LSS) were analyzed in this paper. The results showed that a 63.5 N LSS of the MRSW joint was obtained under the following conditions: electrode force <inline-formula> <tex-math notation="LaTeX">$F=9.0$ </tex-math></inline-formula> N, welding current <inline-formula> <tex-math notation="LaTeX">$I=1000\text{A}$ </tex-math></inline-formula>, ramping time <inline-formula> <tex-math notation="LaTeX">$t_{1}=5$ </tex-math></inline-formula>ms, welding time <inline-formula> <tex-math notation="LaTeX">$t_{2}=2$ </tex-math></inline-formula>ms and dip in the alcohol for protection. The fracture occurs in the heat affected zone (HAZ). Using metallurgical microscopy observed the nugget, metallurgical fusion could be found, the diameter of nugget was about <inline-formula> <tex-math notation="LaTeX">$\Phi 0.3$ </tex-math></inline-formula> mm, without gas pores. Scanning electron microscopy (SEM) was used to observe the fracture surface. It could be found some “whisker” shape diverged from the joint center to the surroundings in HAZ. The electrode tip was observed by energy dispersive spectroscopy (EDS) and optical profiler. It was found that the tip was uneven and adhered the base metal obviously after spark. Additional work about electrode sticking will be required. The thermal test data showed that the use of ultra-thin Mo-Re sheet can reduce a space TWT cathode heating power (CHP) by 0.57 W, which will effectively save satellite energy and improve the expected working life of vacuum electronic devices.
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