Metallized 95% Alumina Ceramic Parts
Products Description
Metallized 95% Alumina Ceramic Parts use high-purity alumina (Al₂O₃ ≥95%) as the substrate. Advanced metallization processes form a uniform and dense metal layer on specific surfaces, enabling reliable bonding with metal components (such as copper and iron alloys). Product forms include ceramic shells, insulating cylinders, feedthrough components, and support structures, possessing high insulation strength, high airtightness, and excellent thermomechanical stability.
Core Technical Features:
High-purity ceramic substrate: Dense crystalline structure with excellent electrical insulation and arc resistance.
Precision metallization layer: The metal layer forms a strong chemical-mechanical bond with the ceramic substrate, ensuring reliable welds and supporting subsequent brazing or welding.
Optimised thermal expansion matching: The ceramic-metal interface design reduces stress concentration and adapts to rapid temperature changes.
Surface engineering treatment: Optional secondary treatments, such as nickel plating or gold plating after metallization, improve weldability and oxidation resistance.
These features enable the product to effectively suppress arcing, prevent leakage, and dielectric breakdown in high-voltage DC scenarios, and support the evolution of the system to higher voltage platforms.
Design Advantages: Macroscopic Reconstruction of Field Strength Constraints and Fluid Dynamics
| Field Strength Homogenization Surface Design | We optimise our electric field simulation-assisted design. Eliminating sharp corners and right angles, and employing a smooth transition with high curvature, effectively suppresses local electric field distortion and controls the peak surface field strength below the corona discharge threshold. |
| Airflow Guiding Inner Wall Structure | Metallised Welded Ceramic Housing arc-extinguishing cylinder features microfluidic guiding characteristics. During the millisecond-level process of arc generation and airflow expansion, it guides high-temperature, high-pressure gas to flow at high speed along a preset path, accelerating arc elongation and cooling, significantly improving the DC breaking success rate. |
| Gradual Wall Thickness and Stress Buffer Design | For the brazed sealing surface, a gradient wall thickness transition and flexible flange structure design are adopted. While absorbing mechanical vibration and thermal shock, it ensures that the impacts are |
Technical Characteristics: Specially designed for HVDC contactors
High Dielectric Strength
The breakdown field strength of 95% DC Relay Elements Metallized Ceramics is typically ≥15 kV/mm (1mm thickness). Actual component designs incorporate sufficient safety margins based on creepage distance and surface withstand voltage requirements.
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Low Partial Discharge Level
After metallization and assembly, in a vacuum or inert gas environment, the partial discharge initiation voltage (PDIV) can be controlled above the operating voltage of the high-voltage DC system, preventing insulation ageing during long-term operation.
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Thermal Shock Resistance
Withstands instantaneous arc heating from ambient temperature (-40℃) to localised temperatures exceeding 1000℃ without thermal shock cracking. Water quenching tests show that the critical temperature difference ΔT for 95% alumina is >180℃.
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Mechanical Strength
Three-point bending strength ≥280 MPa, sufficient to withstand the impact load at the moment of contactor closure and the preload torque during stud installation.
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Metallization layer solderability
The nickel-plated surface can be automatically brazed using standard silver-copper solder (such as Bag-72Cu) or active brazing filler metal, with a solder penetration rate of ≥95% and no cold solder joints.
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Application Scenarios in Depth
New Energy Vehicles
High-voltage circuits for main contactors, pre-charge contactors, and battery management systems, ensuring safe power transmission.
01
Energy Storage and Grid
High-voltage DC switchgear, inverters, and power distribution systems, adapting to high-current, rapid switching requirements.
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Industrial and New Energy Equipment
High-voltage modules for photovoltaic, wind power, and charging piles, supporting intelligent and high-power-density designs.
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Other Cutting-Edge Fields
High-voltage power supply systems for rail transportation, aerospace, etc., leverage their adaptability to various environments.
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contact us
Whether you are in the prototype development, platform verification, or mass production stage, we can provide one-stop engineering support based on the structural requirements of HVDC contactors, from Aluminum Oxide Metallized Ceramics design and metallization process development to the manufacturing of airtight welded components, to help your project complete verification and achieve stable mass production faster.
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