Manufacturing Process & Quality Assurance

The superior performance and reliability of our vacuum interrupters are rooted in a meticulously controlled, high-precision manufacturing process that integrates advanced materials science, vacuum technology, and stringent quality control.

1. Precision Component Manufacturing

Envelope Fabrication: High-alumina ceramic or borosilicate glass insulation shells are precision-formed and fired to achieve exact dimensions, superior mechanical strength, and exceptional dielectric properties. Metal end caps (typically oxygen-free copper or stainless steel) are machined with high precision.

Contact Production: Core contact alloys (CuCr, CuW) are manufactured via advanced powder metallurgy processes (vacuum melting, sintering) to ensure uniform microstructure, optimal conductivity, and arc erosion resistance. Contacts are then machined to precise profiles (e.g., spiral, AMF slots) and undergo surface polishing and cleaning.

Bellows Manufacturing: Critical stainless steel bellows are formed using hydraulic or electroforming techniques, undergoing rigorous fatigue testing to guarantee thousands of reliable operations without vacuum loss.

2. Ultra-Clean Assembly & Brazing

All components undergo multi-stage ultrasonic cleaning and degreasing in a strictly controlled cleanroom environment to eliminate organic and particulate contaminants.

Assembly is performed in dry air or nitrogen-filled chambers to prevent oxidation.

Critical Ceramic-Metal Sealing: Permanent, hermetic seals between ceramic insulators and metal end caps are achieved through high-temperature (≥800°C) vacuum brazing or active metal brazing (using Ag-Cu-Ti filler). This process is precisely controlled to form a leak-tight, mechanically strong, and electrically stable joint, which is the foundation of the product's lifetime integrity.

3. Vacuum Exhaust & Degassing

The assembled tube is connected to a high-vacuum system via its exhaust port.

A prolonged baking process (typically at 300-450°C for hours) under high vacuum is conducted to outgas moisture and impurities from all internal surfaces.

The tube is then sealed under ultra-high vacuum (final pressure ≤ 10^-4 Pa) by cold-welding the exhaust pipe. This extreme vacuum is the essential medium for insulation and arc extinction.

4. Activation & Electrical Conditioning (Aging/Processing)

After sealing, the interrupter undergoes a controlled "aging" process. A series of high-current arcs are initiated between the contacts by discharging a capacitor bank.

This process cleanses microscopic projections from contact surfaces, further degasses remaining impurities (gettering effect), and stabilizes the internal vacuum level, ensuring consistent dielectric strength from the first operation.

5. Rigorous Final Testing & Quality Control

99% High-Potential Test: Every unit withstands a high DC or power frequency voltage test to verify dielectric strength and the integrity of the vacuum seal.

Leak Detection: Advanced helium mass spectrometer leak testing is employed to guarantee a hermetic seal far exceeding industry standards.

Mechanical Life Test: Sample units from each batch are subjected to extended mechanical endurance cycling to validate the bellows and operating mechanism.

X-Ray Inspection: Used to verify internal alignment, contact gap, and the integrity of critical braze joints.

Production Philosophy: Our manufacturing integrates automation with skilled craftsmanship at critical stages, supported by full traceability and statistical process control (SPC) at every step, ensuring each vacuum interrupter delivers consistent, reliable performance.