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Aluminum Nitride (AlN) Ceramic Substrates for Efficient IGBT Module Cooling

Behind the swift movement of electric vehicles, the operation of photovoltaic power stations, and the precise control of industrial production lines, there is a common core power component – the IGBT (Insulated Gate Bipolar Transistor) module. It converts direct current into alternating current, precisely regulates the motor speed and torque, efficiently controls power switches, and completes the conversion and regulation of electrical energy. It is the “heart” of power electronic devices.

As the industry continuously enhances the performance and efficiency of systems, IGBT modules are evolving towards higher power density, smaller size, and greater reliability to meet the demands of lightweighting in electric vehicles, high power output, efficient operation of new energy inverters, as well as long lifespan and high reliability of industrial frequency conversion equipment. In such applications with high power and high heat load, safely and efficiently discharging the heat generated by the chip has become a major challenge in module design.

This answer is largely hidden within a seemingly insignificant component of the module – the base plate. It is not an ordinary metal plate, but a precise component made of a copper-ceramic-copper composite structure. The substrate of IGBT modules has traditionally been made of ceramic materials. For low-power modules, aluminum oxide, which is cost-effective and has mature manufacturing processes, is commonly used. However, in high-power and high-reliability applications, aluminum nitride has emerged as the key material for modern IGBT substrates due to its high thermal conductivity and excellent insulation properties.

Why aluminum nitride?

Aluminum nitride is an advanced functional ceramic. It is used in high-performance IGBT modules due to its outstanding physical properties:

(1) Excellent thermal conductivity: The thermal conductivity is as high as 170–230 W/mK, which is 6–8 times that of traditional alumina, enabling the rapid transfer of heat generated by the chip to the base plate, thus preventing overheating and failure.

(2) Reliable insulation: While achieving efficient heat conduction, AlN maintains a high volume resistivity and dielectric strength, enabling the construction of a stable electrical isolation barrier at the typical operating voltage of IGBT modules, ensuring operational safety.

(3) Matching thermal expansion: Its thermal expansion coefficient (~4.5×10-6/K) is close to that of silicon chips. During thermal cycling, it effectively reduces thermal stress and prevents the cracking of the soldering layer, thereby enhancing long-term reliability.
However, merely having high-performance ceramics is not sufficient to construct a complete module. It needs to be combined with metals in order to conduct current and dissipate heat.

DBC Technology: From Ceramics to Multi-functional Substrates

In order to fully utilize the material advantages of AlN, modern IGBT modules typically employ the Direct Bonded Copper (DBC) technology. This process achieves the bonding of high-purity copper foil firmly to both sides of the AlN ceramic sheet through a high-temperature eutectic reaction, forming a sandwich structure of copper-ceramic-copper. Each layer has a clear and coordinated function:

-Upper copper layer: As the circuit layer, it is used for soldering IGBT chips and conducting the main current.

-The middle AlN ceramic layer: It is the functional core, achieving both efficient insulation and rapid heat conduction.

-Lower copper layer: As a heat transfer layer, it conveys heat to the metal base plate and the external cooling system.

Through this structure, the AlN-DBC substrate is no longer an isolated ceramic, but becomes a multifunctional integrated carrier that integrates conductivity, insulation, heat conduction and mechanical support, laying a solid physical foundation for the high power density and high reliability operation of IGBT modules.

The core mission of AlN-DBC

In the IGBT module, AlN-DBC determines the performance limit of the module:

(1) Thermal Management
The high thermal conductivity enables the heat generated by the chip to be quickly dissipated, ensuring the stable operation of the module under high current and high power density conditions, and achieving miniaturization and high efficiency.

(2) Electrical insulation
Provide reliable insulation isolation between high-voltage chips and the grounding heat sink to ensure the safe operation of the high-voltage system (such as the automotive 800V platform).

(3) Mechanical Stability
The thermal expansion matching reduces thermal cycling stress, ensuring the interface reliability of the module during frequent start-stop, acceleration, and high-power cycles, significantly extending its service life.

For this reason, AlN-DBC has become the preferred solution for advanced applications such as electric vehicle main drive inverters, on-board chargers (OBC), high-power photovoltaic/storage converters, ultra-fast charging stations, and high-end industrial servo drives. It provides a solid material foundation for performance breakthroughs in these fields.

With the development of power electronics technology, IGBT modules are evolving towards higher power, smaller size and greater reliability. The AlN-DBC substrate provides crucial support for this trend and lays the foundation for future high-temperature applications of wide bandgap semiconductor devices. Innovacera can offer customized solutions for Aluminum nitride (AlN) Substrates, helping customers create high-performance and reliable next-generation power modules. Please feel free to contact us.

HTCC Ceramic Packaging Technology: The Key to High Power and High Frequency Applications

In the modern electronics industry, the three types of ceramic packaging and component technologies, namely HTCC, LTCC and MLCC, jointly form the foundation of high-performance electronic systems.

Although they all belong to the multi-layer ceramic technology system, their application directions and performance emphases are different:

HTCC is used for high-reliability and high-power packaging, LTCC excels in integrating high-frequency and multi-functional circuits, and MLCC is the core type of surface-mount passive components.

These three factors jointly support the high performance and miniaturization development of modern electronic devices.

This article mainly introduces the HTCC packaging technology:

HTCC packaging combines alumina or aluminum nitride porcelain wafers with tungsten/molybdenum metal circuits through a set of precision ceramic-metal co-firing process, and finally forms a high-density, highly reliable three-dimensional ceramic circuit structure through key steps such as molding, printing, co-firing and packaging.

The key steps include:

(1) Ceramic substrate preparation (tape casting):

Mix the ceramic powder (such as alumina) with organic binders, plasticizers and solvents to form a uniform slurry. Then, use a casting machine to shape it into a certain thickness of raw porcelain sheet.

This step requires strict control of drying conditions and slurry viscosity to ensure uniform thickness and flat surface of the raw film, providing a stable foundation for subsequent printing and lamination.

(2) Circuit Printing:

Conductive lines and through-holes are formed on the surface of the raw porcelain pieces through the screen printing process. Using tungsten, molybdenum or their alloys as the metal conductor enables it to withstand the subsequent high-temperature co-firing process.

After printing, it is usually dried and degreased at low temperature to ensure that the metal circuit is firmly adhered to, the pattern is clear, and there are no bubbles and impurities.

(3) Layering and Lamination:

The printed multi-layer preforms are precisely aligned and overlapped, and the interlayer bonding is achieved through heat pressing or isostatic pressing techniques to form a three-dimensional interconnection structure.

The accuracy of this step directly affects the size tolerance of the finished product and the reliability of conduction.

(4) High-temperature co-firing:

In a reducing atmosphere, the ceramics and metal conductors are sintered together at a temperature of around 1600℃ to achieve synchronous densification, thereby forming a robust multi-layer substrate.

The finished product usually undergoes a volume contraction of approximately 15—20%, so compensation for this shrinkage needs to be taken into account during the design stage.

(5) Post-processing techniques:

Carry out processing such as metallization, electroplating, cutting, welding, pin installation or gas sealing on the sintered substrate.

Some of the high-end HTCC products will also undergo solder pre-coating, electrode strengthening or laser marking to meet the demanding requirements of military, medical or high-temperature electronic applications.

Technical Advantages

· Excellent high-temperature stability

The HTCC package can operate stably for a long time in an environment of 300–350°C.

With special design, it can even withstand short-term extreme high temperatures above 400°C.

Its ceramic framework maintains structural integrity and airtightness at high temperatures, which is crucial for achieving high-temperature electronic packaging.

· Outstanding electrical insulation property

The ceramic matrix itself is an excellent insulating material, featuring low dielectric constant and low dielectric loss, which helps ensure the integrity of high-frequency signal transmission and reduces interference.

· High mechanical strength and environmental durability

The structure is sturdy and can withstand thermal shock, mechanical vibration and corrosive environments.

Its reliability is much higher than that of ordinary plastic packaging and it is suitable for use in harsh conditions such as industrial and aerospace applications.

· Support high-density three-dimensional integration

By stacking multiple layers of porcelain tiles and achieving vertical interconnection, a complex three-dimensional wiring structure can be realized, supporting high pin count, high frequency and miniaturized packaging designs.

· Excellent thermal management performance

Ceramic materials (especially aluminum nitride, AlN) have a high thermal conductivity, which can effectively transfer the heat generated by the chip, thereby increasing the power density and service life of the device.

Application Fields

· Automotive electronics: Applied in engine control modules (ECU), pressure sensors and on-board power modules to cope with the high temperatures and vibrations within the engine compartment.

· Industry and Energy: Provides services for core power conversion equipment such as frequency converters and inverter power supplies, ensuring their long-term operation under high temperatures and high power densities.

· High-frequency communication: As the RF circuit and filter carrier in 5G base stations and radar systems, it ensures the low-loss transmission of high-frequency signals.

· Sensor technology: Provides sturdy and airtight packaging shells for various MEMS, gas, infrared and pressure sensors, suitable for harsh conditions.

· High-end equipment: It is the key packaging solution for highly reliable control systems in aerospace, military electronics, and implantable medical devices.

Thus, whether it is to cope with harsh environmental challenges or to achieve the ultimate performance, HTCC ceramic packages offers a proven and reliable path.
When your project is subjected to demanding conditions such as high temperature, high frequency, high power or long-term reliability, HTCC might just be the key solution.
INNOVACERA is dedicated to providing customers with professional HTCC ceramic packaging solutions. Please feel free to contact us.

Why choose zirconia ceramics as a thermal insulation plate?

Zirconia (ZrO₂) ceramics are widely used as thermal insulation plates thanks to their excellent thermal insulation performance, high mechanical strength, and outstanding stability at elevated temperatures. The excellent insulation performance of zirconia ceramics comes from their intrinsically low thermal conductivity, which effectively reduces heat transfer. As a result, zirconia insulation plates are commonly employed in various industrial systems that require reliable thermal barriers.
Below are the key features and advantages:

High-Speed Capability

Zirconia ceramics offer strong cold resistance, low elastic modulus, high compressive strength, low thermal conductivity, light weight, and a low coefficient of friction. These properties allow them to be used in high-speed spindles operating from 12,000 to 75,000 rpm as well as other high-precision equipment.

High Temperature Resistance

Zirconia insulation plates maintain stable performance with minimal thermal expansion across 500–600 °C, making them suitable for applications exposed to significant temperature fluctuations.

Corrosion Resistance

Due to their inherent chemical stability, zirconia ceramics resist corrosion from strong acids, strong alkalis, inorganic salts, organic salts, and seawater. This makes them ideal for electroplating equipment, electronic devices, chemical machinery, shipbuilding, and medical equipment.

Antimagnetic Properties

Zirconia insulation plates are non-magnetic and do not attract dust, reducing premature wear, shaft spalling, and operational noise. They are suitable for demagnetization equipment, precision instruments, and other applications requiring non-magnetic components.

Electrical Insulation

With high electrical resistivity, zirconia ceramics help prevent arc damage to shafts and can be used effectively in electrical equipment requiring stable insulation performance.

Vacuum Compatibility

The self-lubricating, oil-free nature of zirconia ceramics overcomes the lubrication challenges faced by ordinary ceramic plates in vacuum environments, making them suitable for vacuum systems and related equipment.

In addition, zirconia ceramic insulation plates offer excellent impact and wear resistance, contributing to their long service life and overall durability. INNOVACERA manufactures a wide range of zirconia components, allowing users to select products based on specific performance and application requirements. For customized insulation solutions, feel free to contact us.

Pain Points in Thick- and Thin-Film Circuit Fabrication and Ceramic Substrate Advantages

In the pursuit of high performance and high reliability in electronic manufacturing, traditional substrate materials have become increasingly unable to meet the ever more demanding requirements. Limited thermal conductivity, poor high-temperature stability and insufficient surface accuracy are becoming the bottlenecks for the development of thick-film and thin-film circuits. Therefore, the industry urgently needs a new type of carrier that combines excellent insulation, efficient heat dissipation, outstanding dimensional stability and ideal surface flatness to support the printing and sintering processes of precision circuits.

Core performance requirements of thick film/film circuits for the substrate:

In the field of high-performance electronics, thick-film and thin-film circuits are two crucial microfabrication technologies. Although their processing paths are different, they both impose many similar and stringent requirements on the substrate materials that carry their circuits.

Metallized ceramic circuit board

The thick-film circuit is formed by applying conductive, resistive or insulating pastes through screen printing on the surface of the substrate, and then undergoing high-temperature sintering for solidification to create the circuit pattern. The typical sintering temperature is approximately 850℃ – 900℃, and the specific temperature depends on the type of slurry and the substrate. The core of its process requires that the substrate must be able to withstand high-temperature thermal shock, maintain extremely high dimensional stability (without warping or shrinking) and chemical inertness during the sintering process, prevent reactions with the paste, and at the same time, the surface must meet the required flatness and adhesion for printing.

The thin-film circuit adopts processes such as vacuum coating, lithography and etching to fabricate fine lines at the micrometer or even nanometer scale on the substrate. This requires that the surface of the substrate have an extremely low roughness (almost atomic-level smoothness) to ensure the precise formation of the circuits, and it must have excellent uniformity of microstructure and chemical purity to prevent the introduction of defects or impurities during the manufacturing process.

Overall, although the implementation methods of the two technologies are different, they both require that the substrate material must possess excellent thermal stability, precise surface characteristics, outstanding dimensional integrity, and stable chemical properties. Traditional organic or metal substrates often fall short in such high-end applications. However, ceramic substrates are the ideal material designed to address these demanding challenges. Their unique performance combination perfectly meets the ultimate requirements of thick film and thin film circuits for the base carrier.

ceramic substrates

The advantages of ceramic substrates directly address the pain points of high-end circuits

(1) Ultimate thermal stability and dimensional rigidity

Ceramic materials (such as Al₂O₃ and AlN) possess high melting points and excellent thermal stability, which ensures that they do not soften, deform or shrink at the thick film sintering temperature. This “rigidity” ensures precise alignment of multi-layer circuits, reduces internal stress during sintering, and enhances long-term reliability. The thermal expansion coefficients of different materials can be matched with semiconductors or printing pastes, further reducing thermal stress.

(2) Surface and Precision Machinability

For thin-film circuits, the ceramic substrate can be precisely polished to achieve a nanometer-level flatness (Ra), ensuring the accuracy of photolithography and coating processes.; For thick-film circuits, a moderately rough surface can enhance the adhesion of the paste. The ceramic substrate can be flexibly adapted to different process requirements through surface treatment.

(3) Excellent chemical purity and inertness

Advanced ceramic raw materials have high purity, dense structure, and strong chemical stability under high temperatures or in a vacuum environment. During thick film sintering, it will not react with Ag/Ag-Pd and other pastes; In the film manufacturing process, reducing low-volatile impurities can minimize vacuum contamination and defects, thereby increasing the yield of the finished products.

(4) Outstanding thermal management capabilities

High thermal conductivity (AlN can reach 150–200 W/m·K) enables the heat generated by power devices to diffuse rapidly, preventing local overheating and enhancing the reliability and thermal stability of the devices.

(5) Mechanical strength and long-term reliability

The high hardness and high bending strength ensure that the ceramic substrate is unlikely to break during processing, transportation and long-term use; the temperature cycling resistance, moisture heat resistance and corrosion resistance make the ceramic substrate suitable for high-reliability scenarios such as automotive, aviation and industrial control.

Overall, the comprehensive advantages of ceramic substrates in terms of heat, mechanical, chemical and surface properties make them an ideal platform for supporting thick film and thin film precision circuits, and also meet the requirements of high power, high density and high precision in electronic design.

Innovacera offers a variety of ceramic substrate materials to support customers’ diverse applications in thick- and thin-film circuit printing. For inquiries, please feel free to contact us.

The Application Advantages of Silicon Nitride Ceramic Substrates in Electric Drive Systems for New Energy Vehicles

In the electric drive system (motor driver/Inverter) of new energy vehicles, the IGBT power module or power semiconductor module is the core component. They are responsible for converting the direct current (DC) from the battery into alternating current (AC) to drive the motor, while also withstanding high currents, high voltages, and frequent thermal cycles. Silicon nitride (Si3N4) ceramic substrates, with their high thermal stability, high mechanical strength, and excellent electrical insulation properties, have become an indispensable basic material for these power modules.

It is usually used as the internal support and heat dissipation substrate within the module, directly supporting IGBT or diode chips, and combining with the copper leads or metallization layers in the module packaging to form an “insulated and highly conductive” core structure, thereby ensuring the stable operation of the electric drive system under high power density and harsh environments.

Function and Role:

(1)Heat Dissipation

When the power module is operating, it generates a large amount of heat. The silicon nitride substrate conducts the heat quickly to the heat sink or cooling system through its high thermal conductivity, preventing the chip from overheating and enhancing the stability of the module.

The thermal conductivity of silicon nitride (80-90 W/(m·K)) is not the highest, but its unique combination of high thermal conductivity and high mechanical strength makes it an ideal solution for dealing with the intense temperature variations and strong vibration environments of electric drive systems.

(2) Electric Insulation

The IGBT chips inside the power module need to be electrically insulated from the external metal structure, while at the same time ensuring that heat can be conducted. The silicon nitride substrate has high electrical insulation properties and moderate thermal conductivity, meeting the “thermal-conductive insulation” requirement of this design.

This is the fundamental value of ceramic substrates (including silicon nitride, aluminum oxide, and aluminum nitride).

They form the electrical insulation framework of the power module, ensuring that the working voltage of up to several hundred or even thousands of volts is firmly contained within the module, isolated from the grounded casing and the cooling system, thus guaranteeing the basic safety of the system.

(3) Structural Support

The internal chips, pads, and metal layers of the power module all need to be stably supported. The silicon nitride substrate provides high mechanical strength and resistance to thermal stress, preventing the module from warping or cracking under high-temperature thermal cycling.

This is the key factor that distinguishes silicon nitride from other ceramic materials. Its flexural strength and fracture toughness are more than twice that of aluminum nitride. During the intense temperature fluctuations caused by frequent acceleration and deceleration of the vehicle, different materials (chips, solder, substrate, copper layer) within the module will repeatedly undergo thermal expansion and contraction. The excellent structural strength of silicon nitride can withstand such stress, prevent its own fracture or failure of the connection interface, and ensure the long-term stability of the physical structure.

(4) Enhanced Reliability

The electric vehicle undergoes frequent starting and braking operations, and the power module needs to withstand a large number of thermal cycles. Silicon nitride substrates have excellent thermal shock stability, which can significantly enhance the module lifespan and the overall vehicle reliability.

“Thermal shock stability” is the ultimate manifestation of the combined effects of the above three advantages. Because of its good heat conductivity, the temperature changes rapidly, and there is a small internal temperature difference; because of its high strength, it can resist the huge stress generated thereby. Industry data shows that power modules using silicon nitride substrates can achieve a temperature cycling life that is approximately one order of magnitude longer than that of traditional alumina or aluminum nitride substrates, thereby achieving greater durability and reliability. This directly determines the warranty period and durability of the electric drive system, as well as the entire vehicle.

Application Forms:

·Metallized Si₃N₄ Substrate

The surface of the silicon nitride substrate needs to undergo metallization treatment (such as the traditional Mo/Mn method, or the current mainstream active metal brazing/AMB technology) to form metal circuits that can be used for welding and electrical connection. This structure enables it to directly support SiC or IGBT power chips and form the core of electrical interconnection within the power module. Among them, the AMB technology, with its higher copper layer bonding strength and excellent thermal conductivity, has become the preferred solution to meet the stringent requirements of automotive-grade power modules for high power density, long lifespan, and high reliability.

Si₃N₄ Substrate after Active Metal Brazing (AMB)

·Direct Integration in EV Power Modules

In the electric drive system of new energy vehicles, the silicon nitride substrate, which serves as the core carrier for insulation, heat dissipation, and structural support in a “three-in-one” manner, is directly encapsulated within the power module of the main inverter. It fixes the power chip upwards and downwards, and it is closely coupled with the module’s liquid cooling heat dissipation system through thermal conductive materials, achieving efficient heat conduction of the chip. This design ensures that the electric drive system can maintain stable output power and reliable long-term performance even during the intense thermal cycles caused by frequent acceleration and braking.

Innovacera offers a full portfolio of Silicon Nitride (Si₃N₄) Substrates, from standard products to fully customized solutions. For inquiries, please contact sales@innovacera.com.

Innovation Drives The Thermal Energy Revolution: Silicon Nitride Hot Surface Igniters Lead The Way In Efficient Ignition Technology

In industrial thermal energy applications and household gas appliances, the ignition system is a core starting component whose performance directly determines the equipment’s starting efficiency, safety, and service life. Thanks to their superior high-temperature and corrosion resistance, silicon nitride hot surface igniters are gradually replacing traditional ignition components and becoming the preferred solution for high-end ignition scenarios.

As a company dedicated to the research, development, and production of silicon nitride hot surface igniters, we are deeply aware of the importance of this technology to industrial upgrades. This article analyzes the technical principles, application scenarios, core advantages, and comparative benefits in the boiler field to help industry partners gain a deeper understanding of this innovative product.

1. What is a Silicon Nitride Hot Surface Igniter

A silicon nitride hot surface igniter is a new type of ignition device that utilizes silicon nitride ceramic (Si₃N₄) as the core structural and heating matrix, combined with high-temperature resistant heating elements (such as tungsten or molybdenum wire).

Its core working principle is hot surface ignition—when electricity is applied, the internal heating element rapidly heats up, transferring heat to the surface of the silicon nitride ceramic. When the ceramic surface temperature reaches the ignition temperature of the fuel (typically between 300 and 800 °C, depending on the fuel type), it can instantly ignite the gas upon contact, eliminating the need for high-voltage spark ignition.

Structural Composition

The silicon nitride hot surface igniter mainly consists of three components:

Silicon nitride ceramic substrate:

Acts as the core carrier, offering high strength, excellent thermal shock resistance, high insulation, and long-term high-temperature performance above 1300 °C, preventing cracking or leakage hazards.

High-temperature resistant heating element:

Embedded within the ceramic matrix and made of high-melting-point metals or alloys, it rapidly reaches the required ignition temperature without melting during prolonged use.

Electrodes and leads:

Conduct current and maintain a stable connection with the heating element. The outer layer is typically wrapped in high-temperature resistant insulation to ensure circuit safety.

Compared with traditional spark ignition, the silicon nitride hot surface igniter provides more stable and reliable ignition unaffected by humidity, oil contamination, or environmental interference.

2. Application Scenarios

With the key characteristics of high-temperature resistance, corrosion resistance, and stable ignition, silicon nitride hot surface igniters have become the “starting core” of modern thermal energy equipment across industrial, household, and commercial sectors.

2.1 Industrial Thermal Energy Equipment

Industrial boilers and furnaces:

Including gas boilers, oil boilers, hot air furnaces, and ceramic kilns, which require stable ignition in high-temperature, high-dust, and corrosive environments. The corrosion resistance of silicon nitride ceramics ensures long-term, reliable operation.

Industrial burners:

Used in metallurgical heating furnaces and chemical reactors, where frequent, rapid ignition is required. The “instant-on, instant-heating” capability of silicon nitride igniters significantly improves start-up efficiency.

2.2 Household Gas Equipment

Gas water heaters and wall-mounted boilers:

Traditional ignition electrodes are prone to scaling and gas impurities, leading to ignition failure. Silicon nitride igniters, with their smooth surface and anti-scaling properties, extend service life and reduce maintenance frequency.

Gas stoves and integrated stoves:

Operate under direct flame exposure. The high-temperature resistance of silicon nitride ceramics prevents deformation or damage from long-term heat. Moreover, ignition reliability is unaffected by oil dripping from cookware.

2.3 Commercial Thermal Energy Equipment

Commercial kitchen appliances:

Such as large gas frying pans, steamers, and ovens, which operate in high-temperature environments with frequent usage. Silicon nitride igniters adapt well to high-intensity workloads and minimize downtime for maintenance.

Commercial heating equipment:

Large gas heating boilers in hotels and shopping centers must ignite reliably in low-temperature environments. Silicon nitride igniters can operate reliably between -40 °C and 1300 °C, ensuring no ignition failures even in winter conditions.

3. Case Study: Industrial Boiler Upgrade

In one chemical plant, replacing traditional ignition electrodes with silicon nitride hot surface igniters led to the following improvements:

Start-up success rate increased from 85% to 100%.

Replacement frequency of ignition components extended from once every four months to once every two years.

Maintenance downtime reduced by approximately 12 hours per year.

Operation and maintenance costs reduced by more than 40%.

Additionally, the switch completely eliminated safety hazards associated with corrosion and leakage in traditional ignition electrodes.

4. Conclusion

From material innovation to technological implementation, silicon nitride hot surface igniters are redefining ignition system standards through superior performance, providing efficient, reliable, and safe ignition solutions for industrial boilers, household gas appliances, and commercial thermal energy equipment.

As a company dedicated to the R&D and production of silicon nitride hot surface igniters, we will continue to advance in material processing and product design, delivering high-quality products that help our partners reduce costs, increase efficiency, and achieve industrial upgrading and transformation, jointly promoting technological innovation in thermal energy applications.

For more information, please contact us at sales@innovacera.com.

The use of boron nitride ceramic and zirconia ceramic nozzles in different processes of powder metallurgy

In powder metallurgy (PM) processes, boron nitride and zirconia ceramic nozzles are used depending on the type of metal materials.

Main Features of Ceramic Nozzles

High-temperature resistance: withstands temperatures above 1500 °C from molten metals or plasma flames.

Wear resistance: resists erosion from powder or gas flow for long-term operation.

Chemical inertness: does not react with active metals or gases.

Applications at Different Stages of Powder Metallurgy

Stage	Process	Functions of Nozzles	Ceramic Nozzles	Typical Metals
Powder Preparation	Gas Atomization	High-pressure inert gas (such as nitrogen or argon) impinges on the molten metal stream to form fine powder; ceramic nozzles control flow and particle size.	Boron Nitride and Zirconia	High-purity or reactive metals such as titanium and nickel-based alloys.
Powder Preparation	Water Atomization	Ceramic nozzles provide corrosion resistance and precise flow control.	Zirconia	Used in high-pressure water atomization for preparing low-cost powders such as iron-based powders.
Powder Spraying or Deposition	Thermal Spraying	During coating or preform preparation (e.g., plasma spraying or HVOF), ceramic nozzles spray metal powders onto substrates to form dense coatings.	Boron Nitride and Zirconia	Applicable to all metal powders.
Powder Transportation and Treatment	Fluidized Bed or Pneumatic Transportation	Ceramic nozzles are used to control gas flow, evenly disperse or convey powders, and prevent agglomeration or clogging.	Boron Nitride and Zirconia	Tungsten, molybdenum, iron, cobalt, nickel, aluminum, titanium, tantalum, and other active metal powders.
Treatment After Sintering	Cooling or Atmosphere Control	Ceramic nozzles spray inert gases (e.g., hydrogen, nitrogen) or cooling media to control furnace atmospheres and accelerate part cooling to prevent oxidation.	Boron Nitride and Zirconia	High-performance metal powders such as high-speed steel, titanium alloys, and amorphous/metallic glass powders.
3D Printing (e.g., Binder Jetting)	–	Ceramic nozzles are used to accurately spray binders or metal slurries.	Boron Nitride and Zirconia	Powder metallurgy additive manufacturing applications.
Degreasing or Cleaning	–	Ceramic nozzles are used to remove temporary binders or residual powder from compacts.	Zirconia	Titanium and its alloys, nickel-based superalloys, aluminum alloys, cobalt-chromium alloys, refractory metals (tungsten, tantalum, molybdenum), precious metals (gold, silver, platinum), and high-entropy alloys.

Table 1: Boron Nitride Ceramic Nozzle Properties

Properties	Units	BMA	BSC	BMZ	BSN
Main Composition	–	BN + Zr + Al	BN + SiC	BN + ZrO₂	BN + Si₃N₄
Color	–	White Graphite	Greyish-Green	White Graphite	Dark Gray
Density	g/cm³	2.25–2.35	2.4–2.5	2.8–2.9	2.2–2.3
Three-Point Bending Strength	MPa	65	80	90	150
Compressive Strength	MPa	145	175	220	380
Thermal Conductivity	W/m·K	35	45	30	40
Thermal Expansion Coefficient (20–1000 °C)	10⁻⁶/K	2.0	2.8	3.5	2.8
Max Using Temperature (Atmosphere / Inactive Gas / High Vacuum)	°C	900 / 1750 / 1750	900 / 1800 / 1800	900 / 1800 / 1800	900 / 1800 / 1800
Room Temperature Electric Resistivity	Ω·cm	>10¹³	>10¹²	>10¹²	>10¹³
Typical Applications	–	Powder metallurgy, metal casting, high-temperature furnace components, crucibles, casting molds for precious and special alloys, high-temperature supports, and nozzles or transport tubes for molten metals.

Table 2: Zirconia Ceramic Nozzle Indicators

Indicators	Item	Units	MSZ-H	MSZ-L	Custom
Main Composition	ZrO₂	%	≥95	≥95	60–95
	Al₂O₃	%	≤0.2	≤0.2	0.2–20
	SiO₂	%	≤0.4	≤0.4	0.2–1
	MgO	%	≤2.9	≤2.9	MgO / Y₂O₃
	Fe₂O₃	%	≤0.1	≤0.1	0.1–0.3
	TiO₂	%	≤0.1	≤0.1	0.1–1.0
Physical Properties	Color	–	Yellow	Yellow	Yellow / White
	Density	g/cm³	≤5.2	5.4–5.6	4.6–5.6
	Porosity	%	≤18.5	≤8	1–18.5
The stabilizers, grain composition, and porosity can be customized according to specific operating environments.

Mullite:Key Advantages for Heater Components

Generally, mullite is used as a high-temperature material due to its exceptional heat resistance (withstanding temperatures over 1800 °C). It can handle rapid temperature changes without cracking and maintains high structural strength even under extreme conditions.

Main Applications

Advanced Refractories:
Used as inner lining materials for high-temperature industrial furnaces employed in the manufacture of metals, glass, and ceramics.

High-Temperature Parts:
An ideal material for furnace chambers, supports, radiant tubes, and other components requiring superior heat endurance.

Key Advantages for Heater Components

Outstanding High-Temperature Performance:
Maintains structural strength and form stability under extremely high temperatures, with outstanding resistance to deformation.

Enhanced Durability and Service Life:
Excellent thermal shock resistance significantly reduces the risk of cracking and extends the operational life of the components.

Optimized Energy Efficiency:
Promotes uniform heat distribution and efficient heat conduction, effectively reducing overall energy costs.

Superior Chemical Resilience:
Provides excellent resistance to corrosion, performing reliably in diverse furnace atmospheres.

Innova Mullite Plates

Innova specializes in the consistent production of high-quality mullite plates. We offer a range of standardized dimensions and also welcome enquiries for custom specifications based on your provided drawings.

Available Dimensions

Dimension (mm)	Drawing Reference
Φ77.00 × Φ11.00 × 10.00
Φ49.00 × Φ10.00 × 10.00
Φ85.00 × Φ10.00 × 10.00
Φ90.00 × Φ12.00 × 10.00
Φ85.00 × Φ12.00 × 10.00
Φ90.00 × Φ11.00 × 10.00
Φ55.00 × Φ8.00 × 10.00

High Zirconia Ceramic Refractory Parts for Glass Furnaces

Longer furnace life directly translates to lower glass manufacturing costs. Although fused-cast high-zirconia is considered one of the best materials for glass furnaces, its long delivery time and high price have hindered large-scale adoption. Furthermore, poor thermal shock resistance and industry-wide quality control issues have led to significant variations in performance and application outcomes.

A new series of large-size, 5.0 g/cm³ density fused high-zirconia bricks (free from silicon and sodium impurities) effectively addresses common challenges in glass furnace refractory applications. These bricks can withstand long-term operating temperatures up to 2000 °C and provide remarkable performance in environments containing sodium, boron, lead, fluorine, and other glass components, as well as in areas requiring high electrical resistivity.

Under operating conditions above 1550 °C, their lifespan is more than three times that of conventional furnace materials. With strong resistance to molten glass corrosion and erosion, and excellent reheat capability, these materials help extend the service life of glass furnaces, reduce operating costs, and minimize carbon emissions.

Innovacera has launched three types of high-zirconia bricks—MZ-A60, MZ-A80, and MZ-A90—each designed for specific applications and temperature environments in glass manufacturing.

$MZ-A90 Long service life refractory brick-$

Product Types

1. MZ-A60

Temperature Range: Below 1500 °C

Application Environment: Suitable for key parts with large dynamic and thermal gradient spans and high requirements for thermal stability.

Typical Applications: Photovoltaic rolled lip bricks, runner sagger bricks, flow nozzle bricks, stirring rods, stirring paddles, and punches.

2. MZ-A80

Temperature Range: 1550 °C – 2000 °C

Typical Applications: Tank walls of long-life glass furnaces, runners, flow ports, rotating barrels, and hot repair brick-binding sections.

3. MZ-A90

Temperature Range: 1450 °C – 2000 °C

Characteristic: High resistivity (resistance value at 1400 °C/Q.M 680).

Typical Applications: Pool walls, runners, electrode holes, and pool bottoms.

Item		Value
Item		MZ-A60	MZ-A80	MZ-A90
Chemical Indicators	ZrO₂+ HfO₂ /%	≥60	≥78	≥88
	Al₂O₃/%	≥35	≥15	≥0.5
	SiO₂/%	≤0.5	≤0.5	≤9
	Na₂O/%	≤0.2	≤0.2	≤0.2
Room – Temperature Flexural Strength / MPa		≥200	≥300	≥350
Static Glass liquid erosion resistance / (mm/24h) (Borosilicate glass, 1600℃ × 48h)		0.07	0.04	0.03
Creep Rate (1600℃ × 50h) /%		-0.258	-0.165	-0.215
Bubble precipitation rate (Borosilicate glass, 1300℃) /%		≤0.7	≤0	≤0
Bubble precipitation rate (Borosilicate glass, 1500℃) /%		≤1.5	≤0.1	≤0.1
Bulk density （g·cm^-3）		≥4.0	≥5.0	≥4.8
Apparent porosity /%		≤18	≤8	≤10
1100℃ water cooling		≥25	≥3	≥3

Application of High-Temperature Zirconium oxide – Tundish Nozzle(Refractory Nozzle)

Innovacera has introduced a new series of high-performance refractory materials, including photovoltaic rolled lip bricks, runner sagger bricks, flow nozzles, stirring rods, stirring paddles, and punches.

Among these, the Tundish Nozzle—also known as the Pouring Nozzle, Metallurgical Nozzle, or Refractory Nozzle—is a critical component engineered for extreme conditions in continuous casting processes.

$High-Temperature Zirconium oxide - Tundish Nozzle(Refractory Nozzle)$

1. Key Characteristics

Large dynamic and thermal gradient range
High requirements for thermal stability

These properties enable the nozzle to perform reliably under fluctuating thermal and mechanical stresses during steelmaking.

2. How It Works – The Controlled Flow Gateway

In essence, the tundish nozzle acts like a high-temperature precision valve, designed to precisely control the flow of molten steel.

Working in conjunction with the sliding nozzle system, it functions by displacing two sliding plates to open, close, or regulate the molten steel flow channel. This mechanism allows precise control over the initiation, cessation, and velocity of steel flow—ensuring consistent casting quality and process stability.

3. Materials

The nozzle is made from High-Temperature Magnesium-Zirconium (Mg-Zr) composite refractory materials, known for their exceptional thermal and mechanical properties.

4. Advantages

Extremely high temperature resistance (maximum working temperature: 1500 °C)
Excellent thermal shock resistance, preventing cracking during rapid temperature changes
High mechanical strength, ensuring long-term durability under the erosion of molten steel
Good dimensional stability: maintains a stable volume at high temperatures without excessive expansion or contraction

5. Comparative Material Properties

Item	Testing Condition	Sintered Zirconia-Mullite	Electro-fused αβ	ZA60 (Zirconia-Alumina Composite)
Bubble Precipitation (%)	1300 °C × 10 h (Common soda-lime glass)	26	1	0.6
Linear Expansion (%)	1200 °C	0.91	0.95	0.8
Thermal Shock Resistance (Times)	1100 °C Water Cooling	>30	–	–
Bulk Density (g/cm³)	–	2.7	3.5	4
Apparent Porosity (%)	–	16	2	19
Static Erosion Rate	1300 °C × 36 h (Common soda-lime glass)	1.7	0.02	0.02

6. Technical Indicators

Indicators	Item	Units	MSZ-H	MSZ-L	Custom
Main Composition	ZrO₂	%	≥95	≥95	60–95
	Al₂O₃	%	≤0.2	≤0.2	0.2–20
	SiO₂	%	≤0.4	≤0.4	0.2–1
	MgO	%	≤2.9	≤2.9	MgO/Y₂O₃
	Fe₂O₃	%	≤0.1	≤0.1	0.1–0.3
	TiO₂	%	≤0.1	≤0.1	0.1–1.0
Physical Properties	Color	–	Yellow	Yellow	Yellow/White
	Density	g/cm³	≤5.2	5.4–5.6	4.6–5.6
	Porosity	%	≤18.5	≤8	1–18.5

Note: The stabilizers, grain combinations, and porosity can be tailored according to the customer’s specific application and operating environment.

7. Customization and Availability

Reference photos are available. Standard specifications are provided, and custom designs are accepted to meet diverse application requirements.

In conclusion, Innovacera’s Magnesium-Zirconium Tundish Nozzle represents a decade of material innovation and engineering refinement. Designed for superior performance under extreme metallurgical conditions, it offers outstanding resistance to temperature, corrosion, and wear.w

With a global customer base and proven reliability in continuous casting systems, this product stands as a trusted solution for advanced steelmaking operations.

If you are interested in our products or require customized solutions, please feel free tow contact us.

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