At International Syalons Ltd, each of our silicon nitride-based ceramic grades are manufactured onsite from high purity raw materials, and every batch is rigorously analysed using various testing methods, ensuring we continue to produce high quality engineering components.
Producing structural components, such as aluminium window and door frames, copper pipe and wiring, and roof structures requires manufacturing methods that deliver high dimensional accuracy and surface integrity. One such technique for shaping structural components is extrusion, and at the heart of the extrusion process is the die. Manufacturers use ceramic extrusion dies to produce precise, repeatable profiles that retain their accuracy and surface quality over long production runs, even when processing highly abrasive or chemically aggressive feedstocks. Their wear and corrosion resistance, dimensional and thermal stability, and smooth surface finish make them particularly valuable for generating structural components that must maintain exact geometry, defect-free surfaces, and consistent performance under demanding service conditions.
During extrusion, the combined effects of mechanical pressure and frictional heating can cause materials with higher thermal expansion rates to change shape. Even minor dimensional changes in the extrusion die opening can alter the final product’s fit or strength. Ceramic extrusion dies exhibit very low thermal expansion, allowing them to retain their precise shape under elevated temperatures. By offering such stability, ceramic extrusion dies enable the manufacture of structural ceramic components that interlock or align perfectly. This consistency, from the first extrusion to the last, ensures structural components can be assembled without adjustment or loss of structural performance.
Metallic materials used for structural components can be chemically aggressive during the extrusion process. Over time, these chemical interactions can roughen or pit metallic extrusion die surfaces, increasing friction during extrusion and introducing surface defects into the extruded product. Any flaws can weaken the components or shorten their service life in structural applications.
Most of the aggressive chemicals found in structural component feedstocks can be withstood by ceramic extrusion dies due to their chemical inertness. The surfaces of ceramic extrusion dies remain smooth and unchanged by chemical attack, which helps maintain consistent flow characteristics and reduces the risk of flaws that could undermine the strength of the final component.
Sialon ceramic extrusion dies – Image Credit: International Syalons (Newcastle) Ltd.
The surface quality of a ceramic extrusion die directly influences the surface quality of an extruded structural component. If there are irregularities in the extrusion die surface, they can imprint onto the extrudate, producing microcracks or stress concentrations that may weaken load-bearing performance. Manufacturing and polishing ceramic extrusion dies to a high standard can produce exceptionally smooth internal surfaces, reducing friction between the extrusion die and the extruding material and forming cleaner, defect-free surfaces. This elevated surface quality directly contributes to the long-term durability and reliability of structural components in service.
In demanding structural component production, larger steel die casings are fitted with precision extrusion die inserts to handle the most extreme wear and thermal loads. When these inserts are made from advanced ceramics, like silicon nitride or sialon, their performance and service life are significantly enhanced.
Silicon nitride combines extremely high hardness and superior fracture toughness, enabling extrusion die inserts to resist abrasive wear from aggregate-rich feedstocks and reducing the risk of chipping that could produce flaws in load-bearing components. Sialon’s balance of mechanical strength and thermal shock resistance demonstrates its suitability for high-throughput manufacturing environments. Both materials also exhibit low thermal expansion and excellent chemical inertness, allowing ceramic extrusion die inserts to maintain precise profile geometry and a smooth working surface over extended production runs. This combination of thermal, mechanical, and chemical stability enhance extrusion die performance, establishing a consistent output even under the most demanding manufacturing conductions.
Structural components must meet strict requirements for strength, dimensional accuracy, and durability to ensure reliable performance. If the extrusion die loses shape, wears unevenly, or develops surface defects, the resulting products may fail to meet these standards before they even enter service. International Syalons addresses the challenges of die wear, dimensional change, and surface degradation in structural component production by manufacturing advanced ceramic extrusion die inserts formed from silicon nitride and sialon. Our ceramic extrusion die inserts are engineered to exhibit exceptional wear resistance, thermal stability, and chemical inertness. Manufacturers can use them to extend tool life, maintain precise geometries, and deliver consistent, defect-free structural components over long production runs. Reach out to our specialists to uncover more insights about our ceramic extrusion die inserts and how they can improve your structural component manufacturing.
Achieving consistent quality in automotive castings begins with controlling the melt. Whether forming engine blocks or structural EV components, maintaining a uniform temperature and composition in the molten metal is essential for avoiding defects and ensuring performance. Thermocouples provide the necessary temperature data used to regulate furnace conditions, coordinate alloying and degassing steps, and control the timing of casting operations, but in harsh molten environments, they rely on thermocouple protection tubes for accurate, long-term operation. When made from silicon nitride and Sialon, thermocouple protection tubes offer the durability and resistance needed to support precise thermal control and ensure consistent melt conditions.
Thermocouple protection tubes are enclosures designed to house temperature sensors in high-temperature industrial processes. They can be manufactured from many different materials, including metals such as stainless steel, however ceramic variants are typically used in molten metal environments due to their ability to withstand extreme thermal and chemical stress.
Among such materials, silicon nitride and Sialon stand out for their exceptional performance in non-ferrous casting processes. These advanced ceramics offer superior resistance to thermal shock, corrosion, and mechanical wear, making them ideal for protecting thermocouples in molten aluminium and magnesium. By maintaining sensor stability and accuracy, silicon nitride and Sialon protection tubes are crucial for supporting melt consistency across demanding automotive casting operations.
Sialon Protection Tubes – Image Credit: International Syalons (Newcastle) Ltd.
Melt consistency relies on precise thermal control. Silicon nitride and Sialon thermocouple protection tubes maintain the accuracy of the embedded thermocouple through:
Accurate, uninterrupted temperature readings allow foundry operators to manage melt thresholds with greater confidence. As silicon nitride and Sialon thermocouple protection tubes preserve sensor integrity, they help uphold melt consistency throughout the casting process, reducing the likelihood of cold shuts, porosity, and alloying inconsistencies within critical automotive components.
Automotive casting demands durability under extreme and repeated temperature cycling. Thermocouple protection tubes are plunged into molten metal then returned to ambient conditions, often in quick succession. When composed of silicon nitride and Sialon, these thermocouple protection tubes demonstrate resilience under thermal stresses by:
This resilience ensures continuous temperature monitoring during high-volume automotive casting, helping maintain melt consistency and reducing variability throughout the production process.
Each step of the automotive casting workflow, from holding and alloying to degassing and pouring, requires steady thermal input to maintain melt consistency. Sustaining thermal stability throughout the melt process enhances melt consistency and strengthens process control in automotive casting environments. The properties of silicon nitride and Sialon thermocouple protection tubes support this stability through:
Reliable temperature readings across all melt stages promote uniform processing conditions. The result is a more consistent melt profile, supporting higher casting quality and fewer production deviations.
Long-term durability in thermal monitoring is vital for maintaining melt consistency during extended casting campaigns. Sustained reliability over time translates into clear operational benefits, with silicon nitride and Sialon thermocouple protection tubes enhancing process stability by:
Stable sensor performance supports consistent melt conditions across automotive casting operations, improving repeatability and casting reliability.
Sialon Protection Tube in an aluminium melting furnace, and SEM micrograph of a cross-section of the ceramic after use – Image Credit: International Syalons (Newcastle) Ltd.
Reliable melt control depends on accurate, durable thermal monitoring, and that starts with the right protection. Silicon nitride and Sialon thermocouple protection tubes from International Syalons are purpose-built to shield thermocouples in molten metal, maintaining sensor accuracy through thermal shock, corrosion, and mechanical wear. Their performance delivers stable casting conditions, cleaner melts, and longer equipment life. With decades of ceramic engineering expertise, we supply advanced components trusted across the automotive sector. To optimise your casting process, speak with our team about tailored thermocouple protection. We’re ready to provide you with ceramic solutions that ensure accurate thermal control, consistent melt quality, and reduced casting defects.
Low-pressure die casting (LPDC) is a controlled manufacturing method used to produce lightweight, high-strength aluminium car parts including wheels, engine blocks, and suspension components. The process works by applying low air pressure to move molten aluminium from a sealed holding furnace into a steel mold, allowing for accurate filling and minimal porosity. Central to this system is the riser tube, which ensures a clean, steady transfer of metal from furnace to mold. Sialon riser tubes, made from silicon nitride-based ceramics, are particularly well suited to the demands of low-pressure die casting thanks to their resistance to heat, corrosion, and mechanical wear. These properties help maintain stable casting conditions and consistent part quality across production cycles.
Aluminium engine block parts are foundational to the construction of internal combustion engines, providing structural integrity and housing for critical components such as cylinders, bearings, and coolant passages. Yet, consistently casting these parts at scale without compromising quality or cost-efficiency remains a manufacturing challenge. One powerful yet underutilised strategy for improving the casting process is the integration of advanced ceramics, specifically sialon and silicon nitride, into key stages of the workflow. Used strategically, these materials can stabilise the casting process, reduce operational costs, and enhance output quality under the rigorous demands of aluminium engine block part production.
Every car on the road is the result of thousands of engineering decisions, some visible and others buried deep within the chassis. Among these, one of the most fundamental choices is how each component is manufactured. Although often overlooked, the decision to manufacture a component from cast or billet aluminium carries long-term consequences for performance, production speed, and cost.
Aluminium has become vital in automotive design, valued for its ability to reduce weight while maintaining structural integrity. But how it’s processed shapes its final properties. Casting and billet machining offer two very different routes to the same destination: a finished component ready to be bolted into a vehicle.
Ceramics have transformed wire and cable manufacturing, making it possible to produce stronger, more heat-resistant, and longer-lasting components. But innovation comes with obstacles. Brittleness, high production costs, and thermal expansion mismatches can limit their use in wire and cable applications. Rather than barriers, these challenges are driving advancements in ceramic formulations, processing techniques, and hybrid materials, ensuring ceramics continue to push the industry forward.
Wire and cable drawing is a fundamental manufacturing process used to produce precisely sized metal wires for applications in telecommunications, automotive, aerospace, and construction. The process involves pulling metal through a series of dies to reduce its diameter while ensuring uniformity. However, the extreme stress, friction, and heat generated in the wire and cable drawing process place significant demands on the materials used for drawing dies, guides, and capstans.
Traditional materials like tungsten carbide, while durable, suffer from wear over time. This leads to frequent replacements and increased operational costs. Advanced ceramics, Silicon Nitride (Si₃N₄), Sialon (Si-Al-O-N), Zirconia (ZrO₂), Alumina (Al₂O₃), and Silicon Carbide (SiC), offer a superior alternative. The exceptional hardness, wear resistance, and thermal stability of these advanced ceramics make them indispensable in improving efficiency, extending tool life, and enhancing the quality of drawn wire.
High-voltage plasma arcs are indispensable in water treatment, industrial cleaning, waste processing, and more. These industries rely on arc plasma technology to generate intense energy bursts that drive essential chemical and physical processes. However, one significant challenge associated with plasma arcs is the generation of powerful shock waves, which can severely damage electrical insulators at the cathode and anode.Continue reading
As we move through 2024, industrial progress is at a fascinating intersection. The rapid rise of automation and AI is reshaping operational paradigms, while ambitious global climate goals are accelerating the transition to renewable energy and sustainable practices. Across sectors, from manufacturing to energy and beyond, companies are embracing innovation to navigate a challenging global landscape defined by supply chain instability and economic pressures.
At the core of these transformations is a subtle yet significant revolution in materials. Advanced ceramics, especially silicon nitride and sialons, are becoming crucial for this new industrial era. Their outstanding thermal, chemical, and mechanical properties position them as vital contributors in tackling some of the most urgent needs of contemporary engineering: efficiency, durability, and environmental sustainability.
Wire braiding, a specialised process used in industries from aerospace to telecommunications, has undergone significant advancements in recent years—particularly through the integration of technical ceramics. Materials like sialons and silicon nitride are advantageous for the wire braiding industry owing to their high performance under extreme conditions. Here, we’ll explore how ceramic innovations support efficiency, longevity, and performance improvements in wire braiding applications.Continue reading