Kovar Machining

Iron, nickel, and cobalt unite in Kovar alloy to form a metal that replicates the low-thermal-expansion properties of certain glasses and ceramics. This low coefficient of thermal expansion in conjunction with Kovar’s strength and versatility make this a wonderful alloy for an array of applications. Whether you require optimal parts for hermetic sealing or advanced components for aerospace, medical, or electronic equipment design, Kovar machining is often the answer.

What is Kovar?

Kovar is composed of 29% nickel, 17% cobalt, 52+% iron, and a range of trace elements. Due to Kovar’s unique alloy composition, this material is prized for its compatibility with manufacturing processes that require air-tight mating of ceramics and glass with metal. From light bulbs to vacuum tubes and microwave components, hermetic seals are stronger and resistant to a wider range of temperatures with the power of Kovar.

As mentioned, the key benefit associated with Kovar is its low coefficient of thermal expansion. Why is this important? Since many advanced components such as sensitive electronics and aerospace components rely on air-tight seals to prevent moisture and gas penetration, the addition of Kovar promotes material stability, even when components are exposed to a wide range of fluctuating temperatures.

In addition to this primary advantage, Kovar machining also boasts versatile benefits, such as:

Good corrosion resistance:

While not as corrosion-resistant as some other nickel alloys, Kovar still provides a worthy level of resistance to oxidation and corrosive conditions. When paired with a coating or plating, you can expect your Kovar components to outlast many other material types.

Dependable mechanical properties:

Kovar’s balanced alloy composition contributes to its notable structural strength and machinability. Since Kovar has moderate to high ductility, meaning it can be deformed under tensile stress with less risk of fracturing, it is possible to shape complex and intricate components that are strong and less prone to cracking or defects. These balanced properties are invaluable for components used in semiconductors, microwave components, and vacuum tubes that must adhere to complex parameters and maintain air-tight structural integrity.

Versatility for a range of applications:

Thanks to Kovar’s low coefficient of thermal expansion, inherent strength, and overall workability, Kovar machining can add value to many sectors of industry. Kovar is used to improve aerospace equipment, electronic packaging, automotive gadgets, and even medical devices like pacemakers. Wherever a strong, corrosion-resistant, and temperature-stable material is required, Kovar machining is one of the best options available.

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Primary Machining Processes Used for Kovar

We support a spectrum of Kovar machining projects with CNC turning, milling, drilling, and grinding to achieve a precision finish. At the foundation of every Kovar machining project, our experts at Cer-Mac promote project success by providing:

Professional guidance to select the most appropriate machining processes:

When you partner with Cer-Mac, you gain a competitive edge in quality control and Kovar-machining efficiency. We take the time to understand your big-picture project goals, empowering our machinists to connect you with the right machining processes and alloy compositions that will best achieve your core objectives.

Adaptable support for a greater variety of component types:

Whether you are developing an innovative prototype or you require a large-scale component run, our advanced systems are capable of meeting and exceeding your project parameters. Our specialized team can help you trial various shapes and sizes until the prototype has been perfected. Our Kovar machining experts can expedite your bulk component needs with organized production, unparalleled quality control, and national shipping for superior parts delivered on time.

Education and collaborative communication:

As your company’s component needs evolve, our ISO-certified experts are here to advise, keep you informed, and optimize all aspects of the Kovar machining plan as it unfolds and your company grows.

What Makes Kovar Difficult To Machine?

Kovar’s toughness, low thermal conductivity, and ductility all contribute to unique machining challenges. These resilient characteristics cause work hardening during machining, which both increases the heat generated and forces applied to the cutting tools.

Since Kovar alloy resists heat dissipation, the heat generated during high-speed cutting operations is primarily transferred to the work tool. As a result, only specialized cutting tools and coatings that are capable of withstanding high heat are suitable for Kovar machining projects.

Further compounding the difficulty associated with low-thermal conductivity workpieces, hard materials like Kovar increase the abrasive wear that cutting tools experience. Much like Nitronic 60 machining that can strain and prematurely damage cutting tools, correct tool selection and defensive machining practices are crucial to successful Kovar machining.

How To Minimize Tool Wear & Heat Generation During Kovar Machining

To overcome these unique machining challenges, selecting sharp cutting tools with proper geometry and protective coatings is the first step. Specifically, carbide and high-speed steel-cutting tools are commonly employed to ensure precision quality and reduce material hardening during production. Along with appropriate tool selection, workpiece securement, and use of coolant to maintain clean and cool work zone conditions, high-speed cutting in combination with slow feed cycles and shallow cutting depths reduces tool strain and heat generation.

With the right tools, skilled machining techniques, and our organized guidance at Cer-Mac, defect-free Kovar components can be delivered to your door in less time. To learn more about our precision Kovar machining capabilities, reach out to our machinists for an informative consultation today.