Vacuum tube
Reliability

One reliability problem of tubes with oxide cathodes is the possibility that the cathode may slowly become " poisoned " by gas molecules from other elements in the tube, which reduce its ability to emit electrons. Trapped gases or slow gas leaks can also damage the cathode or cause plate (anode) current runaway due to ionization of free gas molecules. Vacuum hardness and proper selection of construction materials are the major influences on tube lifetime. Depending on the material, temperature and construction, the surface material of the cathode may also diffuse onto other elements. The resistive heaters that heat the cathodes may break in a manner similar to incandescent lamp filaments, but rarely do, since they operate at much lower temperatures than lamps.

The heater's failure mode is typically a stress-related fracture of the tungsten wire or at a weld point and generally occurs after accruing many thermal (power on-off) cycles. Tungsten wire has a very low resistance when at room temperature. A negative temperature coefficient device, such as a thermistor, may be incorporated in the equipment's heater supply or a ramp-up circuit may be employed to allow the heater or filaments to reach operating temperature more gradually than if powered-up in a step-function. Low-cost radios had tubes with heaters connected in series, with a total voltage equal to that of the line (mains). Some receivers made before World War II had series-string heaters with total voltage less than that of the mains. Some had a resistance wire running the length of the power cord to drop the voltage to the tubes. Others had series resistors made like regular tubes; they were called ballast tubes.

Following World War II, tubes intended to be used in series heater strings were redesigned to all have the same ("controlled") warm-up time. Earlier designs had quite-different thermal time constants. The audio output stage, for instance, had a larger cathode and warmed up more slowly than lower-powered tubes. The result was that heaters that warmed up faster also temporarily had higher resistance, because of their positive temperature coefficient. This disproportionate resistance caused them to temporarily operate with heater voltages well above their ratings, and shortened their life.

Another important reliability problem is caused by air leakage into the tube. Usually oxygen in the air reacts chemically with the hot filament or cathode, quickly ruining it. Designers developed tube designs that sealed reliably. This was why most tubes were constructed of glass. Metal alloys (such as Cunife and Fernico) and glasses had been developed for light bulbs that expanded and contracted in similar amounts, as temperature changed. These made it easy to construct an insulating envelope of glass, while passing connection wires through the glass to the electrodes.

When a vacuum tube is overloaded or operated past its design dissipation, its anode (plate) may glow red. In consumer equipment, a glowing plate is universally a sign of an overloaded tube. However, some large transmitting tubes are designed to operate with their anodes at red, orange, or in rare cases, white heat.

"Special quality" versions of standard tubes were often made, designed for improved performance in some respect, such as a longer life cathode, low noise construction, mechanical ruggedness via ruggedized filaments, low microphony, for applications where the tube will spend much of its time cut off, etc. The only way to know the particular features of a special quality part is by reading the datasheet. Names may reflect the standard name (12AU7==>12AU7A, its equivalent ECC82==>E82CC, etc.), or be absolutely anything (standard and special-quality equivalents of the same tube include 12AU7, ECC82, B329, CV491, E2163, E812CC, M8136, CV4003, 6067, VX7058, 5814A and 12AU7A).

The longest recorded valve life was earned by a Mazda AC/P pentode valve (serial No. 4418) in operation at the BBC 's main Northern Ireland transmitter at Lisnagarvey. The valve was in service from 1935 until 1961 and had a recorded life of 232,592 hours. The BBC maintained meticulous records of their valves' lives with periodic returns to their central valve stores.
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