Behind every efficient foundry operation lies advanced material science. The performance of molten metal processes depends on materials capable of withstanding extreme temperatures, corrosive environments, and continuous thermal cycling. At Saint-Gobain Performance Ceramics & Refractories, we provide advanced refractory solutions that meet this challenge with precision. Whether controlling heat with immersion tubes, improving efficiency with radiant tubes, or protecting sensors with thermocouple tubes, we are proud to redefine high-performance ceramic design. Each solution combines exceptional thermal conductivity, corrosion resistance, and mechanical strength. Here is how.
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How Saint-Gobain Masters Non-Ferrous Metal Processing
Meeting the Challenges of Non-Ferrous Metal Processing: Saint-Gobain PCR Refractory Tube Solutions
Our High-Efficiency Ceramic Materials for Non-Ferrous Industries
Saint-Gobain’s performance in non-ferrous metallurgy begins with its proprietary materials: NICARB (nitride-bonded silicon carbide) and CERTS (carbon-bonded silicon carbide). Each of these materials provides the foundation for efficient refractory solutions in demanding foundry environments.
NICARB: Nitride-Bonded Silicon Carbide
NICARB is a high-performance ceramic designed for high-temperature stability and resistance to molten metal corrosion. Its fine-grain microstructure is formed through precise sintering. It ensures excellent thermal shock resistance and mechanical integrity.
Regarding immersion and radiant tubes, NICARB delivers uniform heat transfer while maintaining surface strength, preventing wetting by molten metals, and minimizing oxidation. This results in cleaner operations and longer component life, critical matters for continuous aluminium and zinc processing lines.
CERTS: Carbon-Bonded Silicon Carbide
CERTS combines silicon carbide with carbon bonding. This process creates a material that excels in thermal shock resistance and rapid heat response. It offers superior corrosion resistance in aggressive metal baths. CERTS is also ideal for thermocouple protection tubes and immersion tube applications. Its ability to maintain structural integrity under repeated thermal cycling makes it a reliable choice for foundries seeking consistent process control.
Did you know?
Together, NICARB and CERTS contribute to Saint-Gobain Performance Ceramics & Refractories sustainability mission:
- Durable materials reduce replacement frequency
- Lower energy consumption
- Optimized resource use
Indeed, we see it as a concrete way to extend service life and minimize environmental impact across industrial applications.
Refractory Design of Immersion Tubes for Optimal Heat Transfer
In molten metal baths, maintaining stable temperature and minimizing oxidation are constant challenges. Saint-Gobain’s immersion tubes address both through advanced refractory design and material selection. Engineered with optimized internal geometry and controlled wall thickness, these tubes ensure uniform heat transfer while resisting corrosion in aluminium and zinc melts.
By combining NICARB’s high thermal conductivity with CERTS-ZN’s antioxidant glaze, our immersion tubes provide excellent mechanical strength and surface protection.
The outcome aligns with the sector’s highest standards:
- Fewer shutdowns
- Greater process stability
- Optimized temperature control for improved productivity and metal purity
Engineering Innovation in Radiant Tubes for Energy Efficiency
It is well known: in non-ferrous metallurgy, process stability defines product quality. Uniform, contamination-free furnace heating is critical.
Constructed from NICARB, Saint-Gobain’s radiant tubes resist chemical attack from aluminium vapors while maintaining structural strength at elevated temperatures. Their precision-engineered design ensures even heat throughout the furnace. This results in improved energy efficiency and product consistency. Moreover, this innovation supports both cleaner heating atmospheres and extended furnace component life.
Advanced Protection Design for Thermocouple Tubes in Molten Metal
Measuring temperature in molten metals is delicate. Sensors must endure corrosion, shocks, and intense heat. Saint-Gobain’s thermocouple protection tubes are engineered to shield these sensors from harsh operating conditions while maintaining rapid thermal responsiveness.
Manufactured from CERTS and NICARB advanced ceramics, they combine oxidation resistance with exceptional dimensional stability. Therefore, our tubes ensure consistent performance through repeated temperature cycles. Their optimized refractory structure allows accurate, real-time readings without the need for preheating when dry. This provides dependable monitoring in both melting and dosing systems.
Saint-Gobain’s thermocouple protection tubes are available in standard BSP-threaded configurations and lengths ranging from 150 mm to 1 750 mm. They integrate seamlessly into modern foundry equipment, delivering precision, longevity, and process reliability.
The Power of Advanced ISO Pressing: Precision Engineering for Refractory Performance
Finally, Saint-Gobain’s refractory tube excellence is reinforced by cold isostatic pressing (CIP) (also known as ISO pressing). This advanced forming process ensures exceptional material uniformity and mechanical integrity. In this method, ceramic powder is enclosed in a flexible mold and subjected to high-pressure fluid applied equally in all directions.
This isotropic compaction produces components perfectly suitable for subsequent sintering:
- Uniform density
- Superior strength
- Minimal internal stress
Strengthened through the acquisition of Ceramco by Saint-Gobain Performance Ceramics & Refractories in 2024, this technology allows precise control over dimensions and microstructure. It results in highly reliable refractory tubes with outstanding durability and design flexibility for demanding non-ferrous applications.
In terms of capability, CIP allows the production of tubes up to 250 mm in diameter and 1.7 m in length, with minimum wall thicknesses of 7 mm. This capability offers exceptional design flexibility while maintaining uniform strength and density across large components.
Such precision in design and manufacturing reflects our broader expertise in developing reliable refractory solutions for non-ferrous and foundry applications. Through continuous innovation in design and technology, our company’s goal is to continue to drive progress worldwide.