Kovar and Chemical Etching: A Perfect Match for High-Precision Components

What is Kovar?

Kovar is composed of nickel, cobalt, and iron, with trace amounts of manganese and silicon. One of its most distinctive characteristics is its low coefficient of thermal expansion (CTE), meaning it expands and contracts at a similar rate to glass and ceramics. This makes Kovar perfect for sealing metal to glass or ceramic components without causing stress or cracking due to temperature fluctuations.

Top Three Engineering Applications of Kovar

Electronics

Kovar is widely used in electronics, particularly for hermetically sealed components such as vacuum tubes, semiconductor packages, and electrical feedthroughs. Its thermal expansion properties make it ideal for metal-to-glass seals, ensuring the long-term reliability of sensitive electrical devices.

Aerospace and Defence

In aerospace and defence, Kovar is used for critical components that must withstand extreme temperatures and high-stress environments, such as thermocouples, connectors, and satellite interconnects. Its thermal and mechanical stability ensures reliability in harsh conditions.

Automotive

In the automotive industry, Kovar is used for components such as sensors and connectors that must perform reliably in variable temperatures and harsh conditions. Its stability and durability make it an excellent choice for high-performance environments.

Why Chemical Etching is Ideal for Kovar

Photochemical machining is a precise, non-contact method for manufacturing Kovar components, offering significant advantages over traditional machining techniques. Unlike mechanical processes, chemical etching does not introduce mechanical stress, making it ideal for Kovar, which is sensitive to deformation.

The Process

In chemical etching, Kovar is coated with a light-sensitive photoresist, which is exposed to ultraviolet light through a mask to define the desired pattern. After development, the exposed areas are etched away using a chemical solution, leaving behind the intricate design. This process ensures tight tolerances, complex geometries, and minimal material waste.

Precision Micro’s Expertise in Etching Kovar

At Precision Micro, we have decades of experience in chemically etching Kovar, making us a trusted partner for industries requiring high-performance precision components. Our in-depth understanding of Kovar’s material properties allows us to manufacture complex, burr-free parts with industry-leading accuracy.

Our photochemical etching service offers several key advantages:

• Material Integrity: Our etching process preserves the material’s inherent qualities, avoiding mechanical stresses or alterations to its magnetic properties.
• Design Precision: We produce intricate and highly precise designs with tight tolerances, essential for high-performance applications.
• Surface Quality: Our process delivers burr-free components with smooth surfaces, reducing the need for additional finishing.
• Cost Efficiency: By eliminating the need for hard tooling, we provide a cost-effective solution, especially for prototyping and small to medium production runs.
• Industry-Leading Capacity: With over 60 years of expertise, our high-volume production capabilities support growing demand across aerospace, defence, electronics, and medical technology industries.

Conclusion

Kovar’s low thermal expansion, high strength, and stability make it essential for precision engineering. Traditional machining can introduce stress, but photochemical etching provides a precise, stress-free solution.

At Precision Micro, our expertise ensures high-quality, burr-free Kovar components, whether for prototyping or large-scale production. As industries advance, chemical etching remains the most efficient and cost-effective method for manufacturing complex, high-performance components.