Custom Engineered Inorganic Ceramic Fiber Components

1. Product Overview

Custom Engineered Inorganic Ceramic Fiber Components feature precise structures and stable dimensions, making them fully customizable to fit the complex geometries of high-temperature industrial equipment. They are widely used in metallurgical, foundry, heat treatment, power, ceramic, and glass industries, serving multiple functions such as insulation, structural support, gas flow guidance, sealing, and erosion protection.

 

Unlike traditional ceramic fiber boards, Custom Engineered Inorganic Ceramic Fiber Components offer superior mechanical strength and structural integrity. They can be fabricated into a variety of complex shapes, including pipes, elbows, corrugated forms, cones, arches, boxes, and bricks, making them an ideal alternative to conventional refractory bricks or heavy-duty insulation materials.

 

2. Manufacturing Process and Materials

The production of inorganic ceramic fiber special-shaped parts typically involves three key steps:

Pulping and Mixing: High-purity ceramic fiber cotton is mixed with water and inorganic binders such as silicates, aluminates, or alumina gels to form a homogeneous slurry.

Molding and Vacuum Filtration: The slurry is poured into specially designed molds and vacuum-filtered to achieve precise shapes and uniform density.

Drying, Curing, and Finishing: After demolding, parts undergo low-temperature drying, trimming, and sanding to achieve stable strength and accurate dimensions.

Material selection can be tailored to specific temperature requirements, including 1260°C, 1400°C, zirconia-enhanced, or chrome-containing variants.

 

3. Key Features

Exceptional High-Temperature Stability: Suitable for continuous use up to 1350°C with excellent thermal shock resistance.

Precision and Customizability: Manufactured to detailed drawings with tolerances ≤ ±1 mm, accommodating complex geometries.

Low Dust and No Debris: Densely cured, non-friable, and ideal for clean environments.

Lightweight Yet Strong: Low bulk density (typically 250–600 kg/m³) with high structural integrity for rigid support applications.

Outstanding Thermal Insulation: Low thermal conductivity (≤0.18 W/m·K at 1000°C) minimizes heat loss.

Safe and Eco-Friendly: Inorganic composition, free from organic additives, smoke-free, odorless, and compliant with RoHS and REACH standards.

Erosion and Corrosion Resistance: Engineered to withstand high-velocity gas streams and molten metal splashes.

 

 

 

4. Technical Parameters

ITEM	STD	HP	HA	HTZ
Classification Temperature(C°)	1260	1260	1360	1430
Working Temperature(C°)	≤1000	≤1100	≤1200	≤1300
Density(KG/m³)	320-500
Organic Content%	≤1.5
Heating Shrinkage(%)	1000℃×24h≤ -2	1100℃×24h≤ -2	1200℃×24h≤ -2	1350℃×24h≤ -2
Thermal Conductivity(500℃)	≤0.05
Al₂O₃	36-38	39-42	45-47	-
Al₂O₃+SiO₂	≥96	≥98	≥99	-
Al₂O3+SiO₂+ZrO₂	-		-	≥99
ZrO₂	-		-	≥15
Fe₂O₃	<0.5	<0.5	<0.5	<0.5
Na₂O+K2O+Fe2O₃	<0.9	<0.9	<0.9	<0.9

 

5. Product Types

 Common Special-Shaped Structures:

Cylinders / Square Tubes (e.g., thermocouple protection sleeves, insulation tubes)

Elbows / Tees (pipe corner covers)

Arches / Semi-Circles (electric furnace covers, radiation plates)

Cones / Bell Shapes (ladle covers, crucible exteriors)

Prefabricated Bricks / Modules (high-temperature insulation bricks, furnace lining modules)

Boxes (heating device casings, sealed enclosures)

Custom complex parts: corrugated plates, discs, U-shaped channels, stepped components

It can be customized according to your drawings.

 

 

6. Typical Applications

Metallurgy & Foundry: Ladle covers, aluminum covers, flow channels, aluminum insulation sleeves, insulated crucibles, preheating hoods

Industrial Heat Treatment Equipment: Roller kiln doors, electric furnace covers, heater insulation casings, radiation plates, furnace pipe sleeves

Petrochemical Equipment: Reactor shell insulation, pipe elbow liners, flue gas expansion joint liners

Glass & Ceramics: Glass tank covers, insulation rings, flow channel insulation parts, kiln door linings

Power & New Energy: High-temperature coverings for battery production, heater box linings, plasma equipment protective components

Aerospace & Defense: Missile launch platform insulation, engine thermal protection casings, cabin insulation modules

 

7. Packaging & Transportation

Packaging: Cartons, wooden boxes, or palletized loading according to part shape

Shock Protection: Key areas reinforced with padding to prevent damage during transport

Labeling: Each piece marked with model, drawing number, material type, and serial number

Storage: Keep in a dry, ventilated environment to avoid moisture or deformation

 

8. Customization Process

We provide a one-stop solution from design to mass production:

Customer submits working conditions and drawings (or sample parts)

Our engineering team evaluates mold feasibility, material recommendations, and structural optimization

Mold fabrication and sample production for approval

Mass production, quality inspection, packaging, and delivery

If no drawings are available, we also offer structural design support.

 

9. SUNTHERM Advantages

 Complete in-house ceramic fiber production capability (fiber → board → shaped parts → composites)

 Multiple vacuum forming lines, producing oversized shaped parts (up to 1200×1000×500mm)

 Extensive industry experience with export and project-standard customization

 Fast sample turnaround (3–5 days) with reliable delivery schedules

 Comprehensive quality control system; material certifications and inspection reports available

 

10. FAQ

Q1: Can these parts be used in high-temperature liquid environments? Are they resistant to molten aluminum or steel?

A1: Yes. We can enhance erosion resistance with special formulations (high-zirconia, high-alumina) for applications like aluminum ladles, channels, and molten aluminum conduits. Surface hardening or anti-permeation coatings are recommended for extended lifespan.

 

Q2: What is the minimum order quantity? Can I produce just a few samples?

A2: Small batch customization is supported. A single mold can produce a few pieces or even a single prototype. Specific arrangements can be discussed with our sales engineers.

 

Q3: Will these parts shed fibers like ordinary ceramic fiber boards?

A3: No. The finished parts are dense and edges are secure, with minimal fiber dust, making them suitable for high-cleanliness environments such as battery and semiconductor production.

 

 

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