Technical Ceramics
Industry-Leading Ceramic-to-Metal Feedthroughs and Connectors
Morgan Technical Ceramics delivers custom ceramic-to-metal feedthrough assemblies that enable critical signal and power transmission across hermetically-sealed barriers. Our feedthroughs combine exceptional electrical insulation with superior mechanical strength, maintaining ultra-high vacuum integrity and reliable performance from cryogenic conditions to operating temperatures >593°C (>1100°F).
Voltage range capabilities
Our feedthroughs span the complete voltage spectrum, from precision low-voltage signal transmission up to 12kV, through to high-voltage applications exceeding 100kV DC. Each feedthrough is engineered to deliver optimal performance while maintaining exceptional dielectric strength exceeding 30kV/mm.
Specialised configurations
Morgan's engineering expertise extends to water-cooled and RF feedthroughs specifically designed for demanding applications including CO2 lasers, sputtering systems, and plasma generation equipment. These specialised feedthroughs integrate advanced thermal management with superior electrical performance.
Morgan's Comprehensive Feedthrough Portfolio
Feedthroughs classifications
- Low and high voltage feedthroughs
- Feedthroughs for low and high voltage are typically custom designed to meet specific customer requirements. The method of interconnection (number of conducting pins) is flexible with options ranging from single-pin assemblies all the way up to 100-pin+ assemblies
- Feedthroughs for low voltages (up to 12 kV) typically to convey a signal
- High-voltage feedthroughs (20 to 100 kV)
- Water-cooled feedthroughs and RF feedthroughs
- Water cooled feedthroughs and RF feedthroughs are designed to operate efficiently in a variety of RF applications including CO2 lasers, sputtering and plasma generation.
Materials used in feedthrough assemblies
- Ceramics - High purity alumina (95 to 99.8% Al2O3) including A950, AL-998®, Deranox™ 970, Sintox™ FF and Deranox™ 995, along with proprietary zirconia toughened alumina (ZTA) options
- Ceramic glazes - for protection or to facilitate cleaning
- Brazing - conventional gold/nickel alloys or active braze alloys (ABA®)
- Metals - OFHC copper, stainless steels, kovar, monel, nickel alloys and titanium
Why work with Morgan?
- Proven Expertise - Decades of experience in ceramic-to-metal sealing and brazing technologies.
- Custom Engineering Support - Tailored feedthroughs/connectors from concept to full production.
- Material Excellence - High-purity alumina ceramics (95–99.8% Al₂O₃) and a wide range of metals including OFHC copper, stainless steels, kovar, monel, nickel alloys, titanium and thermocouple alloys.
- Hermetic Integrity - Leak-tested to 1x10⁻¹⁰ mbar L/s He for ultra-high vacuum (UHV) performance.
- Extreme Durability - Operating temperatures from -250°C to +450°C and resistance to corrosive or caustic environments.
- Advanced Brazing - Conventional gold/nickel alloys and active brazing (ABA®) with Morgan Wesgo® braze alloys.
- Global Manufacturing Footprint - vertically integrated ISO-certified facilities.
Feedthrough expertise across critical industries
- Scientific -Mass spectrometry, gas detection and high vacuum connectors, microscopes (TEM, SEM), particle accelerators and nuclear detectors
- Medical - active implants, x-ray equipment, scanners and imaging applications
- Aerospace - fire sensing/protection, satellite propulsion systems and engine management
- Industrial - CO2 and Excimer lasers, optoelectronics and power tubes
- Power Generation - power feedthroughs for fusion
- Oil and Gas - deep sea repeaters and penetrators
Feedthough questions
What is a hermetic feedthrough?
A hermetic feedthrough is a sealed component that carries electrical signals, high voltage, high current, gases or fluids through the wall of a sealed chamber without breaking the vacuum or pressure barrier inside it. Morgan's feedthroughs are built to hold ultra-high vacuum integrity even under demanding operating conditions, elevated temperatures, cryogenic conditions, or harsh operating environments.
How is a ceramic-to-metal seal achieved?
A ceramic-to-metal seal is created by permanently joining a ceramic insulator, typically alumina, to a metal housing using specialised metallisation and brazing processes. The ceramic surface is first prepared with a metallised coating, allowing a braze alloy to form a robust bond between the ceramic and metal components. Careful selection of materials ensures compatible thermal expansion characteristics, helping maintain seal integrity during thermal cycling and mechanical stress. The design can be configured as a single-pin, multi-pin, or thermocouple feedthrough depending on the application.
What temperature limits apply to ceramic-to-metal feedthroughs?
The temperature capability of a feedthrough depends on the design, materials and operating environment. Ceramic-to-metal feedthroughs are often selected for applications that exceed the performance limits of polymer-based sealing technologies, offering excellent stability at elevated temperatures and during thermal cycling. Factors that influence temperature performance include the ceramic grade, metal alloy selection, braze material and whether the application operates in vacuum, pressure or corrosive environments. Morgan Technical Ceramics works closely with customers to determine the most suitable feedthrough design for the specific temperature requirements and operating conditions to maintain joint integrity.
How do I get going on my custom feedthrough project?
Getting started is simple. Share your application requirements with our experienced engineering team, including details such as operating voltage, current, pressure, vacuum level, temperature range, environmental conditions and available installation space. We can then recommend an existing solution or develop a fully customised ceramic-to-metal feedthrough tailored to your performance requirements. From design support and material selection through to prototyping and production, our engineers work collaboratively with customers to deliver reliable hermetic sealing solutions for even the most demanding applications. Contact us - +1 (508) 995 1725 ext 371 commercial.nbd@morganplc.com