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Abstract: The design work of 95 GHz, 100 kW gyrotron for Active Denial System (ADS) application is reported in this manuscript. The mode selection is performed considering the various technical constraints. Particle-in-Cell code and indigenously developed code based on the generalized non-linear formalism are used in the beam–wave interaction computation and cavity design. Both the codes show good similarity in results. In addition, the design of electron beam source of 364 kW beam power, beam tunnel, depressed collector and RF window are also discussed. The design results confirm the RF power >100 kW with ≈50% tube efficiency. [Copyright &y& Elsevier]

Highlights: [•] The complete electrical design of 42GHz, 200kW gyrotron is presented. [•] Un-depressed collector and axial output system for RF power is selected. [•] Various commercially available design tools as well as in-house developed computer codes are used in the design process. [•] The experimental results of cold cavity analysis are also presented. [•] The design results show more than 200kW power with 40% interaction efficiency at 42GHz frequency. [Copyright &y& Elsevier]