Corrosion Resistance & Chemical Stability of Advanced Ceramics

Advanced ceramics have garnered growing attention across critical industries due to their exceptional corrosion resistance and chemical stability, especially under harsh environments such as high temperatures, strong acids/bases, and corrosive gases. Compared with metals and engineering plastics, advanced ceramics offer unmatched longevity and performance in chemically aggressive conditions, making them indispensable in semiconductor processing, chemical industries, aerospace, and energy applications.

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Hardness of Ceramics: Properties, Comparison & Applications

What Is Corrosion Resistance and Why Does It Matter?

Corrosion resistance refers to a material’s ability to maintain its structure and performance when exposed to chemical environments—such as acids, alkalis, and salts—without degrading.

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 bonding. This gives them much better resistance to corrosion than most metals and engineering plastics.

For advanced ceramics, this property is crucial because:

  • It extends component lifespan in chemical reactors, furnaces, and gas pipelines.
  • It prevents contamination, which is vital in semiconductor and biomedical applications.
  • It maintains mechanical integrity even under thermal and chemical stress.

Chemical Stability Advantages of Advanced Ceramics

  • Inertness in Acidic/Alkaline Environments: Ideal for reactors, pump liners, seals.
  • Oxidation Resistance: Especially SiC and Si₃N₄ at high temperatures.
  • No Galvanic Corrosion: Ceramics are electrically insulating.
  • No Environmental Stress Cracking: Unlike many plastics.
  • Biocompatibility: Safe for use in biomedical and food contact equipment.

Factors Affecting Corrosion Resistance of Ceramics

  • Grain boundary purity: Impurities can create micro-galvanic sites.
  • Porosity: Dense ceramics perform better in corrosive environments.
  • Phase composition: Certain secondary phases may dissolve in chemicals.
  • Operating temperature: Some ceramics oxidize or degrade above 1000°C.

Dissolution Rate of Ceramics in Aggressive Media (Experimental Data)

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

Material Medium Temperature Duration Dissolution Rate (mg/cm²/day)
Alumina (Al₂O₃) HCl (10%) 100°C  24 h ~0.02
Zirconia (ZrO₂) H₂SO₄ (30%) 150°C  24 h ~0.015
ZTA20 HCl (10%) 100°C  24 h ~0.025
Silicon Nitride (Si₃N₄) NaOH (20%) 80°C  72h ~0.01
Aluminum Nitride (AlN) DI Water (pH 7) Room Temp 7 days ~0.5
Silicon Carbide (SiC) HNO₃ (50%) 120°C 48 h  <0.01
Beryllium Oxide (BeO) HCl (10%) 90°C 24 h ~0.02
Hexagonal BN (h-BN) H₂SO₄ (98%) 100°C 24 h  ~0.15
MGC (Machinable Glass Ceramic) NaOH (10%) 80°C 24 h ~0.2

Note: Materials like AlN and MGC are more reactive in water or alkaline solutions, while SiC and Al₂O₃ demonstrate extreme inertness in both acid and base.

*Data is for reference only.

Key Ceramic Materials: Properties and Use Cases

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

Material Chemical Stability Highlights Common Applications
Alumina (Al₂O₃) Highly inert in acidic and basic media Semiconductor fixtures, medical implants
Zirconia (ZrO₂) Stable in acid; limited alkali resistance Pumps, valves, sensors
ZTA20 Improved toughness and corrosion resistance Structural components, wear parts
Silicon Nitride (Si₃N₄) Strong against acids and thermal oxidation Gas turbines, automotive engine parts
Aluminum Nitride (AlN) Good chemical resistance, high thermal conductivity Electronic substrates, heat sinks
Silicon Carbide (SiC) Excellent resistance to virtually all chemicals Chemical reactors, seals, heat exchangers
Beryllium Oxide (BeO) Chemically stable, thermally superior Military electronics, space systems
Boron Nitride (BN) Inert, non-reactive even at high temperatures Crucibles, insulators in reactive atmospheres
Machinable Glass Ceramic (MGC) Good chemical resistance, easy to machine Prototypes, vacuum parts

Related knowledge points:

  • Chemical Bonding: Ionic and covalent bonds in ceramics make them less reactive.
  • Passivation: Some ceramics (e.g., ZrO₂, SiC) form stable oxide layers that resist further attack.
  • No Metal Oxidation: Ceramics do not rust or corrode like metals.
  • No Softening: Ceramics maintain strength and do not swell or dissolve like polymers.

Need Help Choosing the Right Ceramic?

Selecting the right advanced ceramic is critical to ensuring long-term reliability and optimal performance. Whether you need silicon nitride, silicon carbide or alumina ceramic materials, our materials offer industry-leading performance, durability and precision.

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

Comparative Corrosion Resistance of Common Materials

This figure shows the dissolution rate comparison (unit: mg/cm²/day) of various advanced ceramic materials in three typical corrosive media, which facilitates intuitive understanding of the chemical stability of various advanced ceramic materials in acid, alkali 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 ceramic Corrosion Resistance

  • Ceramics Used: Silicon Nitride (Si₃N₄), Silicon Carbide (SiC), Alumina (Al₂O₃)
  • Application Example: In the transportation of highly corrosive fluids such as hydrochloric acid, sulfuric acid, or sodium hydroxide, metal components corrode easily. SiC ceramic pump housings, impellers, and sleeves are used to extend service life and reduce maintenance frequency.
  • 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 (e.g., RCA cleaning), highly corrosive chemicals like hydrofluoric acid, ozonated water, and hydrogen peroxide demand chemically stable materials. High-purity alumina ceramic valve seats and pump seals ensure purity and durability.
  • Advantages: Chemically inert, no ion contamination, high-temperature stability.

  • Ceramics Used: Silicon Carbide (SSiC), Zirconia Toughened Alumina (ZTA)
  • Application Example: In desulfurization towers, corrosive gases like SO₂ and HCl cause severe damage to equipment. SiC ceramic nozzles and heat exchanger linings resist both chemical corrosion and particle erosion.
  • Advantages: Corrosion and erosion resistance, greatly extended service life.

  • Ceramics Used: Silicon Nitride (Si₃N₄), Alumina (Al₂O₃)
  • Application Example: FCC units operate in sulfur-containing high-temperature environments. Metal thermowell housings degrade quickly, while silicon nitride ceramic thermowell tubes maintain accurate temperature monitoring over extended use.
  • Advantages: High thermal and chemical stability, thermal shock resistance.

  • Ceramics Used: Zirconia (ZrO₂), High-Purity Alumina (Al₂O₃)
  • Application Example: During pharmaceutical production, chemical compositions and pH levels vary widely. Zirconia ceramic seals ensure biocompatibility and chemical resistance while maintaining mechanical strength.
  • Advantages: Chemically stable, biocompatible, no ion leaching.

  • Ceramics Used: Alumina (Al₂O₃), Silicon Carbide (SiC)
  • Application Example: In caustic paper making or acidic dyeing environments, metal blades corrode or wear quickly, affecting product uniformity. Ceramic blades provide longer service life and better coating consistency.
  • Advantages: Corrosion and wear resistance, non-contaminating.

  • Ceramics Used: Silicon Carbide (SSiC), Silicon Nitride (Si₃N₄)
  • Application Example: During rare earth separation or HF leaching, traditional metals fail rapidly. Ceramic linings and paddles resist HF corrosion and mechanical impact.
  • Advantages: Cost-effective replacement for expensive alloys like tantalum or Hastelloy.

  • Ceramics Used: Alumina (Al₂O₃), Silicon Carbide (SiC)
  • Application Example: In reverse osmosis (RO) systems, seawater’s high salinity corrodes metal parts. Ceramic components resist chloride ion corrosion and scaling, ensuring long-term stability.
  • Advantages: Long-lasting, anti-scaling, chloride-resistant.

  • Ceramics Used: Aluminum Nitride (AlN), Beryllium Oxide (BeO), Silicon Carbide (SiC)
  • Application Example: In nuclear reactors or radioactive waste treatment, metal materials deteriorate in harsh environments. Advanced ceramics offer chemical inertness and low neutron absorption.
  • Advantages: Radiation resistance, high chemical stability, long service life.

  • Ceramics Used: Zirconia (ZrO₂), Alumina (Al₂O₃)
  • Application Example: Beverage filling systems require materials that do not react with acidic contents. Ceramic components ensure corrosion resistance and food-grade safety.
  • Advantages: Food-safe, corrosion-resistant, non-leaching.

Related high thermal conductivity ceramics

Silicon Nitride Ceramics-High Thermal Shock Resistance Material

Silicon Nitride Ceramics

Silicon Carbide Ceramics-High Thermal Shock Resistance Material

Silicon Carbide Ceramics

Alumina Ceramic - high temperature resistant ceramics

Alumina Ceramic

Zirconia ceramics-thermal insulation ceramics

Zirconia Ceramics

Frequently Asked Questions (FAQ)

Silicon carbide (SiC) typically ranks the highest due to its exceptional inertness in both acidic and oxidizing conditions.

Yes. In many cases, advanced ceramics like alumina, zirconia, and SiC show significantly better corrosion resistance than SS316L, especially in acids and high-temperature applications.

Most advanced ceramics show extremely low dissolution rates in acids. Exceptions include AlN and MGC, which are less stable in moisture or alkaline solutions.

Ceramics are generally more resistant to chemical corrosion but can be more brittle under mechanical stress.

Yes. High-density (low-porosity) ceramics show better corrosion resistance due to reduced surface area exposure.

No. Their stability depends on the chemistry of both the ceramic and the medium. For example, AlN hydrolyzes in water.

Metals tend to corrode via electrochemical reactions, especially in acidic or saline media. Ceramics are inorganic, non-metallic, and chemically bonded in ways that resist most corrosion mechanisms.

Yes, materials like alumina, silicon carbide, and ZTA offer broad-spectrum corrosion resistance. However, zirconia and AlN may degrade in strong alkali over time.

Very few materials resist HF well. Even alumina and silica-based ceramics may dissolve in HF. Use BN or specific fluorinated materials in such conditions.

Thermal conductivity of silicon carbide ceramics

Flexural strength