Fired Refractory Shapes

Fired Refractory Shapes

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The Thermal Ceramics business manufactures a wide range of fired refractory shapes has been produced both in the United Kingdom and the USA for over 60 years, and is used in an extensive range of critical, heat intensive applications.

Using traditional and state of the art manufacturing techniques, fired shapes can be designed specifically for your application. These techniques would include thixotropic and chemical casting, hydraulic and isostatic pressing, extrusion, slip and freeze casting.

We manufacture our fired shapes using a wide range of materials such as high alumina, sillimanite, silicon carbide, fused silica, alumina-zirconia-silica (AZS), zirconia, zircon and mullite. Dependant on your application, our teams of experts will select the material and method best suited to produce your product to your specification.

Cast compositions can be made to precise customer specifications. Thixotropic casting uses a dispersion agent, which allows the mix to flow when vibrated without requiring a high water content. These manufacturing techniques, combined with precisely controlled firing and 100% product inspection, produce high-quality components suited to the most arduous of high-temperature environments.

Fired Shape Properties:

  • Compositions include high alumina, fused zirconia mullite, sillimanite, silicon carbide and AZS
  • Superior hot strength
  • Excellent chemical attack resistance
  • Excellent thermal shock resistance
  • Low gas permeability
  • Tight tolerance capability
  • Trade as Cerox® in USA

Typically, these fired shapes are for the vacuum induction melting (VIM) of super alloys and nickel-based steel alloys. Designs would include crucibles, tundishes and launder systems. Our Thermal Ceramics business is a world leader in the design, manufacture and installation of pouring refractories for the vacuum induction melting industry. We also supply furnace spouts, distribution boxes (often referred to as hot tops), samplers, and “Metamic” (metal-ceramic composite) thermocouple sheaths for the VIM market, along with muffles, ladle liners, saggars, sealed quench furnace muffle assemblies and other special shapes for other markets.

Consumable glass-contact refractories are also made by this method in sillimanite and alumina-zirconia-silica materials (Valcor in the USA) with many standard industry patterns available.

High Frequency Induction melting crucibles up to 300kg capacity are generally made by Isostatic pressing at very high pressures. Materials have been specifically developed to give long life under the most arduous conditions, particularly zirconia, magnesia and alumina.cast crucibles are available from 100kg up to 3 tonnes capacity, mainly in a high alumina composition.

  • Excellent thermal shock resistance
  • Extremely high temperature capability
  • Uniform density throughout material body
  • Materials include zirconia, magnesia, alumina, sillimanite, chrome alumina, and mullite
  • Hydraulic pressing allows simple, high volume parts to be made more cost effectively.

Again, a wide range of materials is offered to produce a wide variety of high quality, precision parts, for example:

  • Nozzles – zirconia,alumina and sillimanite
  • Kiln Furniture – high alumina, mullite and zirconia
  • Reheat furnace insulation bricks (Insuloc) – cordierite, sillimanite and high alumina

Freeze casting allows complex shapes to be made to very tight tolerances, without the need for machining. An excellent surface finish is achieved and generally parts can be made with thinner sections, thus reducing thermal mass.

  • Excellent dimensional stability
  • Excellent Thermal Shock Resistance
  • Thin and complex shape capability
  • Materials include Silica, Silicon Carbide, Alumina and Sillimanite

We offer bespoke designs in an extensive range of materials to provide the most effective solution for your application.