Kovar in Feedthroughs
The Gold Standard for Hermetic Sealing
Learn how Kovar alloy enables superior performance in hermetic feedthroughs that provide reliable electrical connectivity, while maintaining perfect vacuum and pressure seals in mission-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 are an essential interface between hermetically sealed environments and external systems, delivering electrical signals, power or fluids while preserving 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, allowing for perfect, stress-free seals even under extreme temperature fluctuations.
Feedthrough Fundamentals
The main purpose of a feedthrough is to pass through a barrier (wall, chamber or enclosure) while maintaining the integrity of the barrier. For demanding applications this means materials that can make permanent, leak-tight seals and withstand operational stresses.
Electrical Feedthroughs
Kovar offers a number of conductor configuration options for vacuum and pressure applications that have high voltage/current requirements.
Fluid Feedthroughs
Kovar parts that are precision machined provide leak-tight passages for liquids and gases in systems that maintain a controlled environment.
Environmental Protection
Acts as a barrier against corrosive elements while retaining electrical continuity.
Thermal Resistance
Offers seal integrity from cryogenic to 500°C+ operations Wide temperature ranges.
Why Kovar is Superior for Feedthrough Applications
Kovar’s unique combination of material properties addresses the critical issues in the design and performance of feedthroughs.
Thermal Expansion Matching
Kovar’s coefficient of thermal expansion (3.3 x 10-6/°C) is quite close to that of borosilicate glass which removes thermal stress in the seals during temperature cycling.
- Reduces material fatigue over time
- Minimizes seal failure risk
- Stable performance across temperature extremes
Ultra-Hermetic Sealing
Provides permanent leak-tight seals that preserve vacuum integrity and pressure containment in the most demanding operating 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
Complex geometries can be achieved and operational stresses withstood due to the high tensile strength and excellent machinability.
- 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 design, with borosilicate glass as the electrical insulator and hermetic seal between the Kovar conductors and the 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 demanding higher temperature resistance and superior electrical insulation properties.
- Operating temperatures up to 800°C
- Superior dielectric strength
- Excellent thermal shock resistance
High-Power Feedthroughs
Kovar feedthroughs are designed for heavy duty applications with high current handling capability, thermal stability and hermetic integrity.
- Current ratings up to 1000A
- Integrated heat sinks available
- Low thermal resistance designs
Custom Engineered Feedthroughs
Custom Kovar Feedthroughs Designed to Meet Specific Dimensional, Performance and Environmental Specifications.
- 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
For wafer fabrication in a vacuum processing chamber that provides electrical connections while maintaining ultra-high vacuum conditions.
Aerospace & Defense
Military hardware and propulsion equipment essential for satellite systems that need to operate reliably in harsh environments.
Medical Devices
Diagnostic equipment and therapeutic devices requiring sterile environments for use in MRI machines – vacuum sealed.
Industrial Processing
For plasma processing equipment, controlled atmosphere manufacturing systems, vacuum furnaces.
Space Exploration
Reliable feedthroughs for spacecraft instrumentation, propulsion systems and communications equipment.
Energy Sector
Applications in nuclear instrumentation, fuel cell technology and high temperature energy production systems.
Scientific Research
Vacuum chambers and experimental physics apparatuses are essential elements of particle accelerators.
Underwater Technology
Pressure tight feedthroughs for subsea instrumentation, ROV’s 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 parts with tolerances as close as ±0.001mm, ensuring precise dimensional control for reliable sealing.
Glass-to-Metal Sealing
Hermetic integrity is guaranteed by proprietary sealing processes in controlled-atmosphere furnaces, which produce the ideal bonds between Kovar and glass.
Hermeticity Testing
All feedthroughs are tested with helium mass spectrometry, confirming leak rates below 1×10-10 Pa.m3/s, guaranteeing reliable operation.
Electrical Testing
Complete verification of electrical performance including dielectric strength, insulation resistance, and current carrying capacity.
Need Custom Kovar Feedthroughs?
Our engineering team has experience in designing and building custom Kovar feedthroughs to meet your 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
