FLEXIBLE REPEATER MANUFACTURE 



127 



80 

 75 

 70 

 65 

 60 



^ 55 



V 



^50 



LU 



o 



CL 

 40 



35 



30 



25 

 20 



JFMAMJJA5ONDJFMAMJJASONDJFMAMJJASON0 

 1954 1955 1956 



Fig. 6 — Mica capacitor yield. 



attachments were necessary to wind these resistors. Other resistors were 

 hand wound on methyl-methacrylate forms, or on the outside of the 

 ceramic containers, for certain types of paper capacitors. Rough adjust- 

 ments were required of the lengths of resistance wire prior to winding, 

 and close adjustments to resistance values were made after the windings 

 were completed and before leads were attached to resistors. Again it was 

 necessary to provide periodic samples that could be placed on life test 

 by the Laboratories to ascertain that the manufacturing processes were 

 under control. These samples, in all possible cases, were taken from prod- 

 uct that would normally be rejected because of some minor defect, but 

 which would not in any way detract from the validity of the life tests. 

 The making of hard solder splices between nichrome resistance wire 

 and gold-plated copper leads, and keeping ceramic parts from coming 

 in contact with metal surfaces and thereby being contaminated because 

 of the ceramic's abrasive characteristics, were two major problems on 

 resistors. Fig. 7 indicates resistor jdelds. 



Inductors comprised 20 different designs, most of which were air core, 

 but there were some for which it was necessary to cement permalloy 

 dust cores into pockets of the methacrylate form, and thereafter using 



