Kovar in Feedthroughs
The Gold Standard for Hermetic Sealing
Discover how Kovar alloy enables superior performance in hermetic feedthroughs, providing reliable electrical connectivity while maintaining perfect vacuum and pressure seals in critical applications.
Ultra-Hermetic
Leak rates as low as 1×10-10 Pa·m³/s
Technical Overview
Kovar Feedthroughs: Essential Components for Sealed Systems
Hermetic feedthroughs create a critical interface between sealed environments and external systems, enabling the transfer of electrical signals, power, or fluids while maintaining vacuum integrity or pressure containment.
Kovar (ASTM F-15) has become the material of choice for high-performance feedthroughs due to its unique thermal expansion characteristics that match borosilicate glass and certain ceramics—enabling perfect, stress-free seals even under extreme temperature fluctuations.
Feedthrough Fundamentals
A feedthrough’s primary function is to penetrate a barrier (wall, chamber, or enclosure) while maintaining the barrier’s integrity. In demanding applications, this requires materials that can form permanent, leak-tight seals while withstanding operational stresses.
Electrical Feedthroughs
Kovar enables multiple conductor configurations in vacuum and pressure environments, withstanding high voltage and current demands.
Fluid Feedthroughs
Precision-machined Kovar components create leak-tight pathways for liquids and gases in controlled environment systems.
Environmental Protection
Provides barrier against corrosive elements while maintaining electrical continuity.
Thermal Resistance
Maintains seal integrity across extreme temperature ranges from cryogenic to 500°C+ operations.
Why Kovar is Superior for Feedthrough Applications
Kovar’s unique combination of material properties addresses the most critical challenges in feedthrough design and performance.
Thermal Expansion Matching
Kovar’s coefficient of thermal expansion (3.3 x 10-6/°C) nearly perfectly matches borosilicate glass, eliminating thermal stress in seals during temperature cycling.
- Reduces material fatigue over time
- Minimizes seal failure risk
- Stable performance across temperature extremes
Ultra-Hermetic Sealing
Creates permanent, leak-tight seals that maintain vacuum integrity and pressure containment even in the most demanding operational environments.
- Achieves 1×10-10 Pa·m³/s leak rates
- Maintains integrity over extended service life
- Resists permeation of gases and moisture
Mechanical Strength & Durability
Combines high tensile strength with excellent machinability, enabling complex geometries while withstanding operational stresses.
- Tensile strength up to 690 MPa
- Resists vibration and mechanical shock
- Compatible with various assembly methods
Kovar vs. Alternative Materials
When compared to stainless steel, titanium, and other alloys, Kovar offers distinct advantages for critical feedthrough applications:
Kovar Feedthrough Types
We manufacture a comprehensive range of Kovar feedthroughs tailored to specific application requirements, from standard configurations to custom-engineered solutions
Glass-Sealed Feedthroughs
The most common Kovar feedthrough configuration, utilizing borosilicate glass for electrical insulation and hermetic sealing between Kovar conductors and housing.
- Single and multi-pin configurations
- Voltage ratings up to 50kV
- Custom pin layouts available
Ceramic-Sealed Feedthroughs
Kovar components bonded with advanced ceramics for applications requiring higher temperature resistance and superior electrical insulation properties.
- Operating temperatures up to 800°C
- Superior dielectric strength
- Excellent thermal shock resistance
High-Power Feedthroughs
Heavy-duty Kovar feedthroughs engineered to handle high current loads while maintaining thermal stability and hermetic integrity.
- Current ratings up to 1000A
- Integrated heat sinks available
- Low thermal resistance designs
Custom Engineered Feedthroughs
Bespoke Kovar feedthrough solutions designed to meet specific dimensional, performance, and environmental requirements.
- Custom flange configurations
- Specialized conductor materials
- Integrated connectors and terminations
Kovar Feedthroughs Across Industries
Kovar feedthroughs play a critical role in numerous industries where reliable hermetic sealing and electrical connectivity are essential.
Semiconductor Manufacturing
Used in vacuum processing chambers for wafer fabrication, providing electrical connections while maintaining ultra-high vacuum conditions.
Aerospace & Defense
Critical components in satellite systems, propulsion equipment, and military hardware requiring reliable performance in extreme environments.
Medical Devices
Used in MRI machines, vacuum-sealed diagnostic equipment, and therapeutic devices requiring sterile environments.
Industrial Processing
Essential for vacuum furnaces, plasma processing equipment, and controlled atmosphere manufacturing systems.
Space Exploration
Reliable feedthroughs for spacecraft instrumentation, propulsion systems, and communication equipment.
Energy Sector
Used in nuclear instrumentation, fuel cell technology, and high-temperature energy production systems.
Scientific Research
Critical components in particle accelerators, vacuum chambers, and experimental physics equipment.
Underwater Technology
Pressure-tight feedthroughs for subsea instrumentation, ROVs, and underwater communication systems.
Advanced Manufacturing Processes
Producing high-performance Kovar feedthroughs requires specialized manufacturing techniques and strict quality control to ensure reliable performance.
Precision Machining
Our CNC machining centers produce Kovar components with tolerances as tight as ±0.001mm, ensuring perfect dimensional control for consistent sealing.
Glass-to-Metal Sealing
Proprietary sealing processes in controlled-atmosphere furnaces create perfect bonds between Kovar and glass, ensuring hermetic integrity.
Hermeticity Testing
Every feedthrough undergoes helium mass spectrometry testing to verify leak rates below 1×10-10 Pa·m³/s, ensuring reliable performance.
Electrical Testing
Comprehensive electrical performance verification including dielectric strength, insulation resistance, and current carrying capacity.
Need Custom Kovar Feedthroughs?
Our engineering team specializes in designing and manufacturing custom Kovar feedthrough solutions tailored to your specific application requirements.
1.Engineering Expertise
Decades of experience in hermetic sealing and feedthrough design
2.Rapid Prototyping
Fast turnaround for prototypes and small production runs
3.Volume Production
Scalable manufacturing capabilities for high-volume requirements
4.Complete Documentation
Comprehensive test reports and material certifications
