Waveguide flange system

A method for constructing a waveguide flange system, the method comprising:

• forming a first waveguide flange on a first microwave component, the first waveguide flange having a central bore, a first weldable weld plate, the first weld plate extending in all directions orthogonal to the central bore, and a first knife edge projecting from the first waveguide flange in a direction parallel to the central bore and surrounding the central bore;
• forming a second waveguide flange on a second microwave component, the second waveguide flange having a central bore, a second weldable weld plate, the second weld plate extending in all directions orthogonal to the central bore, and a second knife edge projecting from the second waveguide flange in a direction parallel to the central bore and surrounding the central bore;
• placing a deformable gasket between the first waveguide flange and the second waveguide flange, the gasket oriented to contact and engage both the first knife edge and the second knife edge;
• tightening a flange clamp assembly to apply a uniform compressive force to the first waveguide flange and second waveguide flange and deform the gasket with the first knife edge and second knife edge to form an RF seal therein;
• tack welding exposed portions of the first weld plate to corresponding portions of the second weld plate;
• removing the flange clamp assembly;
• and
• completing the weld of the first weld plate to the second weld plate to form a vacuum seal therein.