Glass-to-metal Seal - Matched Seal

Matched Seal

In a matched seal the thermal expansion of metal and glass is matched. Copper-plated tungsten wire can be used to seal through borosilicate glass with a low coefficient of thermal expansion which is matched by tungsten. The tungsten is electrolytically copper plated and heated in hydrogen atmosphere to fill cracks in the tungsten and to get a proper surface to easily seal to glass. The borosilicate glass of usual laboratory glassware has a lower coefficient of thermal expansion than tungsten, thus it is necessary to use an intermediate sealing glass to get a stress-free seal.

There are combinations of glass and iron-nickel-cobalt alloys (Kovar) where even the non-linearity of the thermal expansion is matched. These alloys can be directly sealed to glass, but then the oxidation is critical. Also, their low electrical conductivity is a disadvantage. Thus, they are often gold plated. It is also possible to use silver plating, but then an additional gold layer is necessary as an oxygen diffusion barrier to prevent the formation of iron oxide.

While there are Fe-Ni alloys which match the thermal expansion of tungsten at room temperature, they are not useful to seal to glass because of a too strong increase of their thermal expansion at higher temperatures.

Reed switches use a matched seal between an iron-nickel alloy (NiFe 52) and a matched glass. The glass of reed switches is usually green due to its iron content because the sealing of reed switches is done by heating with infrared radiation and this glass shows a high absorption in the near infrared.

The electrical connections of high-pressure sodium vapour lamps, the yellow lamps for street lighting, are made of niobium alloyed with 1% of zirconium.

Historically, some television cathode ray tubes were made by using ferric steel for the funnel and glass matched in expansion to ferric steel. The steel plate used had a diffusion layer enriched with chromium at the surface made by heating the steel together with chromium oxide in a HCl-containing atmosphere. In contrast to copper, pure iron does not bond strongly to silicate glass. Also, technical iron contains some carbon which forms bubbles of CO when it is sealed to glass under oxidizing conditions. Both are a major source of problems for the technical enamel coating of steel and make direct seals between iron and glass unsuitable for high vacuum applications. The oxide layer formed on chromium-containing steel can seal vacuum tight to glass and the chromium strongly reacts with carbon. Silver-plated iron was used in early microwave tubes.

It is possible to make matched seals between copper or austenitic steel and glass, but silicate glass with that high thermal expansion is especially fragile and has a low chemical durability.