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Content archived on 2024-05-07

Advanced alumina to metal joining for high temperature performance components


This project aims at providing an advanced alumina (Al203) joining technology for the main following industrial applications:
* Telecommunication, televisions, radio emitters, industrial and scientific equipments. In these domains, Thomson TTE is a worldwide leader in the manufacture and design of a wide range of electronic components such as magnetrons, klystrons, tetrodes, diacrodes and travelling wave guides.
* Capacitive sensors to increase the safety (aim of Alfa Romeo Avio) and efficiency (aim of Ansaldo) of turbofan engines by measuring the clearance between the moving parts (blade tip to case) with a non contact method. Presently, these are not available worldwide, due to the lack of technologies for joining alumina to metal in ultra hot and corrosive environments. These sensors will be developed by Thermocoax.
The industrial targets are defined as follows:
Electronic Power Tube Manufacturing: Joining of a 200 mm in diameter alumina tube to a controlled expansion alloy. Joints must endure exposure at temperatures > 400 C for 20000 hrs.
Capacitive Sensor Manufacturing: Joining of alumina tube to Pt, Pd or Ni base alloys. Joints must withstand an operational temperature of 1200 C in oxidising atmospheres for 1000 hrs. The sensors should survive 500 thermal cycles and have a resistivity better than 4kQ at 1200 C.

To fulfil the manufacturing requirements of these Alumina Metal industrial components, the project will develop and demonstrate the effectiveness of new joining materials and processes and establish an engineering design methodology. The developed advanced components will allow European industries to maintain their leadership and share of their worldwide markets as well as the economic benefits (anticipated to be in excess of 100 MECUs totalled over 5 years) associated with efficiency increases, performance enhancements and reduced operational costs.

The practical objectives of this research project are:
* Develop enabling joining technology
* Develop and verify an approach based on an engineering design methodology
* Develop joining methods that lead to a reduction by a factor of 3 of the manufacturing costs of the power tube family products, and that are suitable to accommodate the stringent constraints imposed by the sensor design.
* Using the developed joining methods, manufacture and test under in service conditions the two components as described above.

Call for proposal

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Thomson Tubes Electroniques
EU contribution
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74202 Thonon les Bains

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Total cost
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Participants (6)