OXIDATION
The Problem: Surface Degradation and Structural Failure
Oxidation is a major cause of component failure in high-temperature industrial systems. In processes involving air, chlorine gas, molten metals, or acidic vapors, materials are continuously exposed to aggressive conditions that compromise surface integrity, reduce strength, and shorten equipment life.
Key oxidation challenges include:
- Brittle oxide layer formation, particularly silica-based films that crack and spall
- Grain boundary attack, accelerating microcrack formation and propagation
- Thermal cycling, causing oxide-ceramic interface stresses and delamination
- Reactive gas exposure, such as chlorine or sulfur compounds, increasing surface instability
International Syalons offers engineered ceramic materials that withstand oxidation at extreme temperatures through dense microstructures, non-wetting surfaces, and stable oxide layer formation. These materials are designed for long-term operation in chemically aggressive thermal environments.
- ΔT = 900°C
- Oxidation rate: 0.02 mg/cm²/h
- ΔT = 600°C
How It Works
Sialon ceramics are formulated to slow or stop oxidation mechanisms by design:
- Grain Boundary Engineering: Low amorphous phase content minimizes oxygen diffusion pathways
- Dual-Phase Stability: The combination of α and β SiAlON phases limits crack growth during oxidation
- Self-Sealing Surface Layer: Silica-rich protective film forms on exposure, preventing deeper oxidation
- BN Reinforcement (Syalon 110): Increases resistance to slag infiltration and thermal oxidation
These materials outperform alumina and many standard silicon nitrides in demanding thermal and chemical environments
Tested for Long-Term Exposure
Syalon 050, when tested at 1400°C in air, showed less than 0.1% mass gain after 500 hours of continuous exposure — an industry-leading result that translates to extended component life, reduced surface degradation, and greater process stability.

- Application-specific testing
- Custom component design and prototyping
- Material selection tailored to gas, slag, or thermal profile

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.

