Precision and Performance in HF-ERW Tube Production with Nilcra® Ceramic Rolls and Guides

Advanced Engineering for Demanding Applications

In continuous steel and aluminium tube production, especially in High Frequency - Electric Resistance Welding (HF-ERW), tooling must withstand extreme conditions while delivering consistent quality. Nilcra^®, an advanced grade of sintered silicon nitride (Si₃N₄), is engineered to meet these challenges head-on.

Morgan Technical Ceramics manufactures high-performance welding rolls and guides using Nilcra^® — a monolithic ceramic material known for its exceptional strength, toughness, and wear resistance, even at elevated temperatures.

Key Benefits of Nilcra^® Ceramic in ERW Applications

• Exceptional Wear Resistance
  Maintains hardness and structural integrity under high thermal and mechanical stress, resisting deformation, galling, and corrosion.
• Non-Conductive & HF-Compatible
  Unaffected by the high-frequency electric field, Nilcra^® ensures stable performance without drawing power from ERW equipment.
• Cooler Operation
  Unlike steel rolls, ceramic rolls stay cooler during operation, enhancing bearing life and reducing energy consumption.
• Improved Tube Quality
  Low friction and minimal surface abrasion lead to smoother tube finishes and lower scrap rates.
• Operational Efficiency
  Manufacturers benefit from:
  
  • Reduced downtime
  • Higher yields
  • Scaled-down tooling inventories
  • Better process control

Industries That Benefit from Nilcra^®

• Automotive Manufacturing
  For precision tubing in exhaust systems, fuel lines, and structural components.
• Aerospace & Aviation
  Where lightweight, high-strength tubing is critical for performance and safety.
• HVAC & Refrigeration
  For consistent, high-quality aluminium and steel tubing in heat exchangers and piping.
• Construction & Infrastructure
  Supporting durable tubing for scaffolding, pipelines, and structural frameworks.
• Furniture & Appliances
  Ensuring smooth finishes and consistent dimensions in consumer-grade tubing.
• Oil & Gas
  For corrosion-resistant tubing in harsh environments.
• General Industrial Manufacturing
  Where high-speed, high-volume tube production demands robust, low-maintenance tooling.

Material Properties

Ceramics (MgO-ZrO₂ and SiAlON) show:

• Excellent corrosion resistance
• Minimal wear when paired with softer metals
• Chemically inert to Zinc-Aluminium
• Last 2-4x longer in lifetime and use
• Less susceptible to unstable operation

Magnesia Stabilised Zirconia (Nilcra® Zirconia) is suitable for Zinc only lines (Zirconia can be wetted by Aluminium)
Nilcra® SiAlON is suitable for Zinc-Aluminium lines