Development of UHV compatible machined diamond profile gaskets for INDUS-2

Ultra High Vacuum (UHV) compatible demountable joints are needed in Indus-2 (2.5 GeV, 300mA) electron storage ring for connecting Al-alloy vacuum chambers (homogeneous joints) as well as Al-alloy vacuum chambers to well proven stainless steel components like beam diagnostic components and RF-shielded bellow assemblies (heterogeneous joints). Bakeable & reliable diamond profile Al-alloy gaskets have been developed for Helium leak rate less than 2×10−10 Std. CC/sec, which eliminated the need of any Al to SS transition pieces onto the Aluminium vacuum chambers. Salient features of these gaskets are: high reliability, low cost, reduced flange thickness, self alignment, ease in installation, less torque requirement, formability to non-circular shape & ultra cleanliness. These diamond profile gaskets were machined from extruded Al-alloy 6061-T5 pipes using specially developed high-speed steel formed cutting tools. Thermal cyclic tests were carried to check the reliability of these gaskets. No leaks were found even after several bakeouts at 150°C. Non-circular metallic gaskets like the one used in UHV gate valve bonnet seal can also be manufactured using specially developed formed toolings. This paper describes basic design philosophy, manufacturing process and testing details of these gaskets.