EROSION
The Problem: Accelerated Material Loss from Particle and Fluid Impact
Erosion in materials is a persistent and costly issue across industrial processes involving abrasive particles, pressurized fluids, and extreme temperatures. Whether in oil and gas, shot blasting, or metal processing, erosion can quickly degrade component surfaces, leading to downtime, increased maintenance, and compromised system efficiency.
Common erosion challenges include:
- Abrasive particle impact from sand, grit, and slurry in nozzles, valves, and wear surfaces
- High-velocity fluid erosion, particularly in oil/gas hydrocyclones and fluid transport lines
- Material compatibility issues with traditional metals like tungsten carbide, which suffer from binder erosion
- Thermal stress, which accelerates erosion and crack formation in high-temperature environments
International Syalons offers a suite of sialon ceramics engineered for extreme erosion resistance. These materials are designed to maintain strength, surface integrity, and dimensional stability in the face of high-energy fluid flow and abrasive wear.
- Withstands 40 m/s fluid velocities
- Fracture toughness: 7.7 MPa·m½
- Hardness: 94 HRA
Why It Works
Sialon ceramics owe their superior erosion resistance to:
- Covalent Si-N bonding, providing high hardness and wear resistance
- Elongated β-SiAlON grains, which deflect cracks and resist grain pull-out
- High density (>99%), minimizing porosity and reducing erosion channels
- Thermal and chemical stability, allowing use in molten metals and high-pressure fluid systems
These features combine to deliver extended component life and minimized maintenance, even in the most erosive environments.
Proven Implementation in Demanding Applications
International Syalons’ erosion-resistant ceramics are already used across several high-impact industries:
- Oil & Gas: Syalon 101 hydrocyclones extend maintenance intervals in sand separation systems
- Shot Blasting: Syalon 050 nozzles withstand extreme grit impact, lasting over 1,000 hours in aggressive use
- Metal Processing: Syalon 101 thermocouple sheaths protect measurement systems from molten aluminum erosion

- Application-specific material testing
- Custom component prototyping for complex geometries
- Support for transitioning from metal or alumina-based systems to high-performance ceramics

Sialon and zirconia provide the high temperature strength and non-wetting properties necessary for metal casting, extruding, and welding.

Technical ceramics are characterised by excellent mechanical strength and hardness, and are widely used in extreme wear applications.

Silicon nitride offers excellent corrosion and thermal resistance and are ideal materials for use in the chemical and process industries.
