For most of us, electronic technology comes in the form of solid state devices. Transistors, integrated circuits, microcontrollers. But for the first sixty years or so of the field existing, these devices either hadn’t been invented yet or were at too early a stage in their development to be either cost-effective, or of much use. Instead a very different type of electronic component ruled the roost, the vaccum tube.
A set of electrodes in an evacuated glass envelope whose electrical properties depended on the modulation of the flow of electrons through them, these were ubiquitous in consumer electronics up until the 1960s, and clung on in a few mass-market applications even as far as the mid 1970s. As cheaper and more versatile semiconductors superseded them they faded from electronic parts catalogues, and the industry that had once produced them in such numbers disappeared in favour of plants producing the new devices. Consumer products no longer contained them, and entire generations of engineers grew up never having worked with them at all. If you were building a tube amplifier in the early 1990s, you were a significant outlier. Continue reading “Just Who Makes Tubes These Days?”→
Vacuum tubes fueled a technological revolution. They made the amplification of signals a reality for transatlantic telephone cables (and transcontinental ones too), they performed logic for early computers, and they delivered that warm fuzzy sound for high fidelity audio. But they were labor intensive to produce, and fragile, so semiconductors came along and replaced tubes in almost every application. But of course tubes are still with us and some tube applications are still critical — you’ll find them used in high-power RF and there are even satellites that depend on klystrons. So there are still experts in tube fabrication around, and Charles Alexanian is one of them. His newly-published talk at the 2018 Hackaday Supercon (found below) is a whirlwind tour of what goes into building a vacuum tube.
The process of building your own vacuum tube isn’t hard, but it’s not a walk in the park. The difficulty comes in the sheer number of processes, and the tricks of the trade found at every step. Charles’ methaphor is that if you build one tube at a time each step is like learning to ride a bicycle again, but if you build many you get into the swing of it and things go a lot better. His talk is a brief overview of everything, but if you want to drill down he also wrote an excellent article that goes further in depth.
In the working components of each tube are the precision parts: the grid (or grids). For the tube to function well these must be accurately produced which can be done with photolithography, but Charles usually uses a winding process involving a lathe. After winding, the grid is stretched to straighten the nickel wire, then cut to length. Other components such as the plate are stamped using an arbor press and simple forms he fabricates for the purpose.
Tube sealing machine common in factories
Lathe setup used for 1-off tube sealing
Tube being tested for leaks
Two glass components are used, the dome itself, and feedthrough stems that have a wire for each lead passing through a glass disc. The components are spot welded to the inside portion of the feedthrough stem, then the glass is fused together, again using a lathe. It heads over to a pumping station to evacuate the air from the tube, and is finally tested for leaks using a handheld Tesla coil (see, we knew those weren’t just toys).
Charles proposed his Supercon appearance as a chance to fabricate tubes on-site. We loved the idea, but the amount of gear needed is somewhat prohibitive (annealing ovens, vacuum cabinets, torches for sealing, and the need for 220v, plus space for it all). That’s too bad since we were really hoping to see the Jolly Wrencher in Nixie-tube form — incidentally, Charles says Nixes are simple to make compared to amplifiers and switches. He also mentions that the majority of your time is spent “washing” parts to remove impurities. Fair enough, that part sounds boring, but we hope to endure it at some point in the future because vacuum tube fabrication demos feel very much like a Hackaday event!
The vacuum tube is largely ignored in modern electronic design, save for a few audio applications such as guitar and headphone amps. The transistor is smaller, cheaper, and inordinately easier to manufacture. By comparison, showing us just how much goes into the manufacture of a tube, [glasslinger] decided to make a wire-element pilotron – from scratch!
To say this is an involved build is an understatement. Simply creating the glass tube itself takes significant time and skill. [glasslinger] shows off the skills of a master, however – steadily working through the initial construction, before showing off advanced techniques necessary to seal in electrodes, produce the delicate wire grid, and finally pull vacuum and seal the tube completely.
The project video is an hour long, and no detail is skipped. From 2% thoriated tungsten wire to annealing torches and grades of glass, it’s all there. It’s enough that an amateur could reproduce the results, given enough attempts and a complete shop of glassworking equipment.
The pilotron may be a forgotten design, but in 2018 it once again gets its day in the sun. Overall, it’s a testament to [glasslinger]’s skill and ability to be able to produce such a device that not only looks the part, but is fully functional on an electronic level, as well.
If you asked [Hans_Daniel] what he learned by building a tube audio amplifier with a dozen tubes that he found, the answer might just be, “don’t wind your own transformers.” We were impressed, though, that he went from not knowing much about tubes to a good looking amplifier build. We also like the name — NASS II-12 which apparently stands for “not a single semiconductor.”
Even the chassis looked really good. We didn’t know textolite was still a thing, but apparently, the retro laminate is still around somewhere. It looks like a high-end audio component and with the tubes proudly on display on the top, it should be a lot of fun to use.
When it comes to vintage displays, everyone gravitates to Nixies. These tubes look great, but you’re dealing with a certain aesthetic with these vintage numeric tubes. There is another option. For his Hackaday Prize entry, [castvee8] is making seven-segment displays out of vintage neon lamps. It looks great, and it’s the basis of an all-vacuum tube calculator.
The core of this build are a few tiny NE-2 neon bulbs. These are the same type of bulbs you’ll find in old indicators, and require somewhere around 100 volts to fire. These bulbs are then installed in a 3D-printed frame, giving [castvee] a real seven-segment display, a plus or minus sign, and an equals sign. It’s the beginnings of a calculator, right there.
One of the recent updates to this project is controlling these displays with modern logic. That might be a bit of a misnomer, because [castvee] is using diode steering and a TTL chip to cycle through the numbers 1 to 4. The actual code to do this is running on a microcontroller, though, so that might get a pass. This is just a test, though, and the real project looks to be an all-vacuum calculator. The project is still in its early stages, but there are still months to go in the Hackaday Prize, and we can’t wait to see what comes out of this project.
Picture the scene: you’ve whipped up an amazing new gadget, your crowdfunding campaign has gone well, and you’ve got a couple hundred orders to fill. Having not quite hit the big time, you’re preparing to tackle the production largely yourself. Parts begin to flood in, and you’ve got tube after tube of ICs ready to populate your shiny new PCBs? After the third time, you’re sick and tired of fighting with those irksome little pins. Enter [Stuart] with the answer.
It’s a simple tool, attractively presented. Two pieces of laser cut acrylic are assembled in a perpendicular fashion, creating a vertical surface which can be used to press pins out of IC tubes. [Stuart]’s example has rubber feet, though we could easily see this built into a work surface as well.
The build highlights two universal truths. One, that laser cutters are capable of producing elegant, visually attractive items almost effortlessly, something we can’t say about the garden variety 3D printer. Secondly, all it takes is a few little jigs and tools to make any production process much easier. This is something that’s easy to see in the many factories all over the world – special single-purpose devices that make a weird, tricky task almost effortless.
There is disquiet in the world of vacuum electronics, that something as simple as shipping a vacuum tube could now be very difficult to achieve. It’s a concern expressed among other places in a video by [Guitologist] that we’ve included below, and includes tales of vacuum tubes being impounded as either dangerous to ship, or not allowed to be shipped across international borders.
Upon investigation it appears that the common thread in all the stories lies with eBay’s Global Shipping Program, the centralised shipping service operated by the online auction giant. We reached out to eBay’s press office on the subject but have yet to receive a reply. It’s best to ask someone who ships a lot of tubes for comment when you have a tube shipping story, so we also had a conversation with TC Tubes. They’re a small company dealing in tubes, and as you might imagine they ship a lot of them (Their website is likely to detain you for a while if you are a tube-head). [Chelsea] from TC Tubes told us that they have encountered no regulatory barriers to tube shipping, and that their only bad experience has been yet again with eBay’s Global Shipping Program.
So it seems there is no cause for panic if you ship tubes, CE marking or RoHS rules haven’t come for your EL34s and your 6550s. Ebay have evidently got some kind of issue with tubes in their shipping operation, and perhaps you should ship by other means if you wish to avoid your tubes going astray. The consensus here among the Hackaday crew is that it could be as simple as uninformed employees not being aware of what tubes are because they aren’t as common as they used to be. After all, with over a hundred years of history behind them it’s not as though any potential issues with their shipping haven’t been comprehensively explored.
We’d still be interested to hear from eBay on the matter though, if they would care to comment.
