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Understanding Glass-to-Metal Seals (GTMS)

Explaining the fundamentals of glass-to-metal seals: how glass and metal are fused to create airtight, hermetic connections that can withstand extreme pressures and temperatures.

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Understanding Glass-to-Metal Seals (GTMS)

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  1. Importance of Glass-to-Metal Seals in Harsh Environments A comprehensive exploration of how glass-to-metal sealing technology provides critical protection and reliability in extreme operating conditions across multiple industries.

  2. What Are Glass-to-Metal Seals? Glass-to-Metal Seals (GTMS) are hermetic seals created by bonding glass with metal to form a durable, airtight, and moisture-proof barrier. They are primarily used in connectors, feedthroughs, and electronic packages to protect sensitive components from harsh environmental conditions. Types of GTMS: • Matched Seals – Glass and metal have closely matched thermal expansion rates (e.g., Kovar alloy + glass). • Compression Seals – Metal compresses the glass during cooling, creating a strong, high-pressure seal.

  3. Core Benefits in Harsh Environments Hermetic Integrity High Pressure & Temperature Resistance Electrical Insulation and Signal Integrity Prevents moisture and gas ingress while maintaining vacuum-tight seals, essential for sensitive components. Engineered specifically for extreme conditions with exceptional durability under stress. Enables reliable passage of electrical/optical signals through sealed housings without degradation.

  4. Why Choose Glass-to-Metal Seal Technology? Superior Long-Term Reliability Inorganic Material Advantage Especially in high-temperature, corrosive and high-pressure environments where other materials fail. No aging or degradation like polymers, making it suitable for rugged/durable applications. Extreme Operating Ranges From cryogenic up to +1000°C in some designs, with pressure tolerance of thousands of bar.

  5. Engineering Challenges and Design Considerations CTE Matching Coefficient of Thermal Expansion matching is critical to maintain seal integrity through temperature cycling. Mismatch leads to stress and seal failure. Material Selection Coupling appropriate glass types with compatible metals (Kovar, stainless steel, titanium) to optimize performance. Manufacturing High-temperature sealing processes require cleanliness and precise process control to ensure hermetic performance.

  6. Application Use-Cases in Harsh Environments Aerospace & Defense Medical Devices / Imaging Satellite systems, aircraft instrumentation, avionics. GTMS ensures vacuum integrity and resistance to wide pressure/temperature swings. Reliable signal feedthroughs with high hermeticity for implantable devices and diagnostic equipment. Semiconductor & Vacuum Systems Oil & Gas / Energy Enabling vacuum-tight packaging and feedthroughs for high-performance instruments. High-pressure and corrosive environments; GTMS can be designed to withstand thousands of bar.

  7. Comparative Advantage to Other Sealing Technologies Parameter Glass-to-Metal Seals Epoxy/Polymer Seals Temperature Range Very high (up to 1000°C) Limited; degrades with heat Chemical Resistance High (acidic, alkaline, oils, gases) Moderate Longevity Decades, minimal aging Potential for aging and failure Electric Insulation Excellent May degrade under stress

  8. Integration Opportunities at EPI Hermetics Specialized Expertise Customization Capabilities As a connector and feedthrough specialist, EPI Hermetics can leverage GTMS competencies to develop customized hermetic components for extreme-use applications. Potential to tailor material selection, seal geometry, and manufacturing processes to client-specific environments. R&D and Prototyping Enabling rapid iterations and testing of GTMS under simulated harsh conditions.

  9. Case Example: Implementation Process 2. Material and CTE Analysis 1. Requirement Gathering Select optimal materials and ensure thermal expansion compatibility Analyze pressure, temperature, electrical feedthrough, and environmental needs 4. Qualification and Deployment 3. Prototype and Testing Final validation and implementation in the field Thermal cycling, leak-rate verification under simulated conditions Key metrics include: leak rate thresholds, operating temperature range, and lifecycle/durability specifications.

  10. Key Takeaways Glass-to-metal seals provide unmatched protection in harsh environments where other solutions fail Superior longevity, temperature resistance, and signal integrity make GTMS the premium choice EPI Hermetics offers specialized expertise to develop custom GTMS solutions for your most challenging applications

  11. CONTACT US Electronic Products Inc. (EPI) has been leading supplier of hermetic microelectronic packages for high-reliability markets.  (978) 462-8101 sales@elecprodinc.com www.epihermetics.com 585 Parker Street Newburyport, MA 01950

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