Corrosion resistance and chemical stability of advanced ceramics

Advanced ceramics have attracted growing attention in critical industries for their superior corrosion resistance and chemical stability, especially in harsh environments such as high temperatures, strong acids/alkalis and corrosive gases. Compared to metals and engineering plastics, advanced ceramics offer unmatched life and performance under chemical corrosive conditions, making them indispensable for semiconductor processing, chemical industry, aerospace and energy applications.

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corrosion resistance

What is corrosion resistance? Why is it important?

Corrosion resistance is the ability of a material to maintain its structure and properties without degradation when exposed to chemical environments such as acids, alkalis and salts.

Advanced ceramics such as alumina (Al₂O₃), zirconia (ZrO₂), silicon carbide (SiC) and silicon nitride (Si₃N₄) are inorganic, non-metallic materials with strong ionic or covalent bonds. This makes their corrosion resistance far superior to most metals and engineering plastics.

For advanced ceramics, this property is critical because:

  • It extends the service life of components in chemical reactors, furnaces and gas lines.
  • It prevents contamination, which is critical for semiconductor and biomedical applications.
  • It maintains mechanical integrity even under thermal and chemical stress.

Chemical Stability Advantages of Advanced Ceramics

  • Inert in acidic/alkaline environments: suitable for reactors, pump linings, seals.
  • Oxidation resistance: especially SiC and Si₃N₄ at high temperatures.
  • No galvanic corrosion: ceramics are electrically insulating.
  • No environmental stress cracking: unlike many plastics.
  • Biocompatible: Safe for use in biomedical and food contact devices.

Factors affecting the corrosion resistance of ceramics

  • Grain boundary purity: impurities create microelectric dip points.
  • Porosity: Dense ceramics perform better in corrosive environments.
  • Phase Composition: Some secondary phases may be dissolved in chemical substances.
  • Operating Temperature: Some ceramics will oxidize or degrade above 1000°C.

Dissolution rate of ceramics in corrosive media (experimental data)

The following table lists the measured dissolution rates of the major ceramic materials in common corrosive media, indicating their long-term chemical durability:

makings medium temp period of time Dissolution rate (mg/cm2/day)
Aluminum oxide (Al₂O₃) Hydrochloric acid (10%) 100°C  24 hours ~0.02
Zirconium oxide (ZrO₂) Sulfuric acid (30%) 150°C  24 hours ~0.015
ZTA20 Hydrochloric acid (10%) 100°C  24 hours ~0.025
Silicon Nitride (Si₃N₄) Sodium hydroxide (20%) 80°C  72 hours ~0.01
Aluminum Nitride (AlN) Deionized water (pH 7) indoor temperature 7 days ~0.5
Silicon Carbide (SiC) ₃ Nitrate (50%) 120°C 48 hours  <0.01
Beryllium oxide (BeO) Hydrochloric acid (10%) 90°C 24 hours ~0.02
Hexagonal boron nitride (h-BN) Sulfuric acid (98%) 100°C 24 hours  ~0.15
MGC (machinable glass-ceramics) Sodium hydroxide (10%) 80°C 24 hours ~0.2

Note: Materials such as AlN and MGC are more reactive in water or alkaline solutions, while SiC and Al₂O₃ exhibit extreme inertness in both acids and bases.

*Data is for reference only.

Main ceramic materials: properties and uses

Click on the blue font to view detailed information on each advanced ceramic material:

makings Chemical Stability Highlights Common Applications
Aluminum oxide (Al₂O₃) Highly inert in acidic and alkaline media Semiconductor devices, medical implants
Zirconium oxide (ZrO₂) Stable under acidic conditions; limited alkali resistance Pumps, valves, sensors
ZTA20 Improved toughness and corrosion resistance Structural components, wear parts
Silicon Nitride (Si₃N₄) Strong resistance to acid and thermal oxidation Gas turbine, automobile engine parts
Aluminum Nitride (AlN) Good chemical resistance and high thermal conductivity Electronic Substrates, Heat Sinks
Silicon Carbide (SiC) Excellent resistance to almost all chemicals Chemical reactors, seals, heat exchangers
Beryllium oxide (BeO) Chemically stable, excellent thermal properties Military electronics, space systems
Boron Nitride (BN) Inert and non-reactive even at high temperatures Crucibles, insulators in reactive atmospheres
Machinable Glass Ceramics (MGC) Good chemical resistance and easy processing Prototypes, vacuum parts

Relevant Knowledge Points:

  • Chemical bonding: Ionic and covalent bonds in ceramics make them less reactive.
  • Passivation: Some ceramics (e.g. ZrO₂, SiC) form a stable oxide layer that resists further erosion.
  • NO METAL OXIDATION: Ceramics will not rust or corrode like metals.
  • No softening: ceramics retain their strength and do not swell or dissolve like polymers.

Need help choosing the right ceramic?

Choosing the right high-strength ceramic material is critical to ensuring long-term reliability and optimal performance. Whether you need zirconia, silicon nitride, or alumina-based ceramics, our materials provide industry-leading strength, durability, and precision.

Our technical team is here to help - contact us today for expert customized advice on your specific needs.

Comparison of corrosion resistance of common materials

The graph shows the comparison of dissolution rates (unit: mg/cm²/day) of various advanced ceramic materials in three typical corrosive media, which makes it easy to visualize the chemical stability of various advanced ceramic materials in acidic, alkaline, and salt environments.

Corrosion Resistance Chart
Click a material to view details.
Click a material above to see its corrosion data and test methods.

*Data is for reference only.

Applications based on the corrosion resistance of ceramics

  • Ceramics used: Silicon Nitride (Si₃N₄), Silicon Carbide (SiC), Aluminum Oxide (Al₂O₃)
  • Application example: When conveying strong corrosive fluids such as hydrochloric acid, sulfuric acid, sodium hydroxide, etc., the metal parts are prone to corrosion. The use of silicon carbide ceramic pump casing, impeller, shaft sleeve and other materials can extend the service life and reduce the frequency of maintenance.
  • Advantages: excellent corrosion and wear resistance, suitable for continuous operation.

  • Ceramics used: high-purity alumina (99.99% Al₂O₃), aluminum nitride (AlN)
  • Application example: In semiconductor cleaning processes such as RCA cleaning, highly corrosive chemicals such as hydrofluoric acid, ozone water and hydrogen peroxide require chemically stable materials. High purity aluminum oxide ceramic valve seats and pump seals ensure purity and durability.
  • Advantages: chemically inert, no ionic contamination, high temperature stability.

  • Ceramics used: Silicon Carbide (SSiC), Zirconia Toughened Alumina (ZTA)
  • Application example: In desulfurization towers, corrosive gases such as sulfur dioxide and hydrogen chloride can cause serious damage to equipment. Silicon carbide ceramic nozzles and heat exchanger liners resist chemical corrosion and particle erosion.
  • Advantages: corrosion and washout resistance, greatly extending service life.

  • Ceramics used: Silicon Nitride (Si₃N₄), Aluminum Oxide (Al₂O₃)
  • Application example: FCC units operate in high temperature environments containing sulfur. Metal thermowell casings degrade rapidly, while silicon nitride ceramic thermowells maintain accurate temperature monitoring even after prolonged use.
  • Advantages: high thermal and chemical stability, good resistance to thermal shock.

  • Ceramics used: zirconium oxide (ZrO₂), high-purity aluminum oxide (Al₂O₃)
  • Application example: During the production of pharmaceuticals, chemical composition and pH values vary greatly. Zirconia ceramic seals ensure biocompatibility and chemical resistance while maintaining mechanical strength.
  • Advantages: chemically stable, biocompatible, no ion leaching.

  • Ceramics used: Aluminum oxide (Al₂O₃), silicon carbide (SiC)
  • Application example: In alkaline paper or acid dyeing environments, metal squeegees tend to corrode or wear out, affecting product uniformity. Ceramic doctor blades provide longer life and better coating consistency.
  • Advantages: corrosion-resistant, wear-resistant, non-polluting.

  • Ceramics used: Silicon Carbide (SSiC), Silicon Nitride (Si₃N₄)
  • Application example: During rare earth separation or hydrofluoric acid leaching, conventional metals can fail rapidly. Ceramic liners and paddles are resistant to hydrofluoric acid corrosion and mechanical shock.
  • Advantage: Economical alternative to expensive alloys such as Tantalum or Hastelloy.

  • Ceramics used: Aluminum oxide (Al₂O₃), silicon carbide (SiC)
  • Application example: In reverse osmosis (RO) systems, the high salinity of seawater corrodes metal parts. Ceramic components resist chloride corrosion and scaling, ensuring long-term stability.
  • Advantages: long-lasting, anti-scaling, resistant to chlorides.

  • Ceramics used: Aluminum Nitride (AlN), Beryllium Oxide (BeO), Silicon Carbide (SiC)
  • Application example: In nuclear reactors or radioactive waste disposal, metallic materials deteriorate in harsh environments. Advanced ceramics are chemically inert and have low neutron absorption.
  • Advantages: radiation resistance, high chemical stability, long service life.

  • Ceramics used: zirconium oxide (ZrO₂), aluminum oxide (Al₂O₃)
  • Application example: Beverage filling systems require materials that do not react with acids. Ceramic components ensure corrosion resistance and food-grade safety.
  • Advantages: food safe, corrosion resistant, no leaching

Important ceramic materials

Silicon Nitride Ceramics-Advanced Ceramic Materials-Zihao Ceramics

Silicon Nitride Ceramics

Silicon Carbide Ceramics-Advanced Ceramic Materials-Zihao Ceramics

Silicon Carbide Ceramics

Aluminum oxide ceramics-Advanced ceramic materials-Chihao Ceramics

Aluminum oxide ceramics

Zirconia Ceramics-Advanced Ceramic Materials-Zhihao Ceramics

Zirconia Ceramics

Frequently Asked Questions (FAQ)

Silicon Carbide (SiC) is usually ranked highest because of its excellent inertness under both acidic and oxidizing conditions.

Yes. In many cases, advanced ceramics such as alumina, zirconia and silicon carbide have significantly better corrosion resistance than SS316L, especially in acidic and high temperature applications.

Most advanced ceramics have a very low rate of dissolution in acids. The exceptions are AlN and MGC, which are less stable in moist or alkaline solutions.

Ceramics are usually more resistant to chemicals, but become more brittle under mechanical stress.

YES. High density (low porosity) ceramics have better corrosion resistance due to reduced surface area exposure.

It won't. Their stability depends on the chemical properties of the ceramic and the medium. For example, aluminum nitride hydrolyzes in water.

Metals tend to corrode by electrochemical reactions, especially in acidic or salt media. Ceramics are inorganic, non-metallic materials that are chemically bonded in such a way that they resist most corrosion mechanisms.

Yes, materials such as alumina, silicon carbide and ZTA have broad spectrum corrosion resistance. However, zirconia and aluminum nitride may degrade over time in strong alkaline environments.

Few materials are well tolerated by HF. even alumina and silica based ceramics may dissolve in HF. in this case, BN or specific fluorinated materials should be used.