Ceramic envelope device, lamp with such a device, and method of manufacture of such devices

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This invention involves a new type of feedthrough-plug member (86) for metal halide HID lamp using PCA envelopes (5). The construction of the lamp housing consists of a PCA envelope (5) and specially designed axially graded alumina-metal cermet multi-layers to eliminate cracking in cermet or PCA due to thermal stresses arising from thermal expansion mismatch. The fills are metal halides such as Na-Sc-I, rare earth halides, Hg, Sn, and inert gases. The PCA vessel (5) and directly sealed cermet-feedthrough assemblies allow the metal halide lamps to operate at high wall temperatures with better lumen output, color temperature, and CRI.