Thanks jiripolivka
Exactly because of expense, and simply how hard it is to find any transitions, I simply bolted the flanges together. They fitted, but looking through from each end, I could see the corners of the square cut off, and from the other side, four small segments of the circle slightly blocked by the sides of the square.
This did not seem to degrade the performance in any way. The joint was in a critical place, at the output of a circular horn feed into a polarizer, before a transmit-reject filter and low noise amplifier. In transmit mode (100W) using the other polarization, there did not seem to be a problem.
When the whole thing is "just working", and the assembly is very high up and takes a long time to align and verify, there is limited value, (or even choice!) in questioning the circle-square join.
I am as surprised as anybody that it works as well as it does. There must be thousands of these out there. Either I am missing something, or it is the best kept secret in the microwave industry? Can it be true that everybody simply bolts these together, and they all "just know" it that just does not matter?
Progress, progress how much soldiers do we need to change damage bulb.
It looks a lot.
looks like most people have forgotten the ways of us ol' microwavers did for a rect. to round transistion ;-)
shape a wooden (preferable to metal) dowel to the size of your rectangular WG, and taper it down.
warm the copper circular WG and gently hammer the tapered dowel into the end of the round WG
keep going till you produce the appropriate sized rectangular opening on the WG.
Mount a retangular WG flange ... DONE
a VERY old, tried and true method !
It can be if you let it, but it need not be.OMT ( ortomode, two polarization) is little bit complicated.
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