Custom Silicon Nitride Liquid Level Probe with OEM Flange and Cable Interface

Applications of Silicon Nitride Liquid Level Probe

• Aluminium Die Casting and Dosing Furnaces

  ✅Key Advantages

  1. Stable dosing volume control
  Helps keep molten aluminium level within a narrow band, supporting consistent shot volume and reducing short-fill defects.
  2. Reduced scrap rate from level-related defects
  By stabilising the metal height at the furnace outlet, the probe contributes to lowering defect rates associated with porosity and misruns.
  3. Longer campaign life between probe changes
  The non-wetting and corrosion-resistant design allows many users to extend replacement intervals and align probe changes with planned maintenance stops.

  ✅ Problem Solved

  An automotive die casting plant operating four dosing furnaces recorded level-related casting defects of around 4–5% when using older level sensors. After adopting silicon nitride liquid level probes and re-setting the level control window, the plant reduced level-related scrap by about 2–3 percentage points and was able to extend the average probe replacement interval from roughly 6–8 weeks to 4–6 months per furnace. The improvement translated into fewer unplanned stops and a noticeable reduction in aluminium waste and re-melt energy consumption over one production year.

• Aluminium Holding Furnaces in Ingot and Foundry Operations

  ✅Key Advantages

  1. Reliable level monitoring during long holding periods
  Supports stable metal height in large holding furnaces that run continuously for many weeks or months.
  2. Support for overflow and dry-out protection
  The probe can be integrated into alarm or interlock circuits to reduce overflow risk and prevent excessive low-level operation.
  3. Performance maintained in dross-forming atmospheres
  The dense silicon nitride surface helps resist attack from molten aluminium and dross build-up over extended campaigns.

  ✅ Problem Solved

  A foundry using a large holding furnace with over 10 tonnes of molten aluminium experienced irregular level readings when using conventional sensors, leading to occasional overflow events and emergency interventions. With a silicon nitride liquid level probe installed at a defined reference position, the furnace team narrowed the operating level band and activated interlocks based on the probe signal. Over the next 12 months, the site reported no overflow incidents related to level control and reduced the time spent on manual level checks by several hours per week.

• Aluminium Launders, Troughs and Casting Lines

  ✅Key Advantages

  1. Local level detection at critical points
  Probes can be positioned in launders or casting channels where stable metal height is essential for downstream mould filling.
  2. Enhanced process stability for continuous casting
  A consistent level in the casting zone supports smoother metal flow and a more uniform ingot or billet surface.
  3. Compact integration into constrained layouts
  Slender silicon nitride probes are suitable for tight launders and can be adapted to existing supports or covers.

  ✅ Problem Solved

  A continuous casting line reported surface irregularities and occasional misfeeds traced to unstable metal height in the launder just before the casting mould. After inserting a compact silicon nitride liquid level probe in this launder and linking it to a level controller, the casting line stabilised the metal height around a defined set point. Over several months of operation, the number of casting interruptions related to metal flow irregularities dropped, and operators were able to maintain more consistent casting speed with fewer manual adjustments.

Si3N4 Liquid Level Probe Usage Instructions

• Installation

  1. Verify that the probe length and mounting interface match the furnace or launder drawing before installation.
  2. Pre-dry and pre-heat the probe gradually in a warm area or preheating chamber to reduce thermal shock before first immersion.
  3. Insert the probe vertically or along the designed angle without striking furnace lining, metal flow channels or other ceramic parts.
  4. Tighten mounting flanges or clamps evenly so that no bending stress is applied to the ceramic body.

• Operation

  1. Keep the probe immersion depth within the specified range so that the active sensing zone is fully surrounded by molten aluminium.
  2. Avoid rapid level swings or uncontrolled metal flow that repeatedly exposes the probe tip to air and metal in seconds.
  3. Monitor level signals after start-up and confirm the switching or measurement corresponds to the expected metal height.

• Storage

  1. Store unused probes in a dry, clean area away from vibration, with support under the full length rather than only at the ends.
  2. Keep ceramic surfaces free from oil, grease and impact from metal tools to prevent micro-cracks before use.

• Cleaning

  1. After removal from service, allow the probe to cool down slowly in still air or insulating material.
  2. Gently remove loose dross or metal residues with non-metallic tools if required; avoid aggressive mechanical grinding of the working surface.
  3. Do not cool the hot probe with water or compressed air, as rapid cooling can cause thermal shock damage.

• Common Misuse Points and Handling

  1. Issue: Probe installed with incorrect immersion depth
  Effect: Level switching point is offset, causing inaccurate level control.
  Handling: Confirm drawing reference position, re-set mounting height or reposition the probe to align the active zone with the required level band.

  2. Issue: Direct flame impingement on the probe above the metal line
  Effect: Local overheating and thermal stress near the freeboard area, leading to cracks over time.
  Handling: Adjust burner or furnace settings, or add a shield to prevent burner flame from hitting the exposed ceramic section.

  3. Issue: Rapid cooling or water contact on a hot probe
  Effect: Severe thermal shock that can fracture the ceramic body.
  Handling: Implement clear procedures for removal and cooling, train operators to let probes cool naturally in a protected area without forced quenching.

FAQ – Silicon Nitride Liquid Level Probe

1. Q: What is a silicon nitride liquid level probe used for in molten aluminium furnaces?
   A: A silicon nitride liquid level probe is used to detect and control molten aluminium level in holding furnaces, dosing furnaces, launders and casting lines so that the metal height remains within a defined window for safe operation and consistent pouring.
2. Q: How long does a silicon nitride liquid level probe typically last in molten aluminium?
   A: Service life depends on alloy, temperature and operating practice, but many users report that a properly installed silicon nitride liquid level probe can operate for several months in continuous aluminium service before replacement is required.
3. Q: Can a silicon nitride liquid level probe replace my existing molten metal level sensor?
   A: In many cases a silicon nitride liquid level probe can replace an existing molten metal level sensor if the active length, mounting interface and electrical connection are matched to your current level control system.
4. Q: What information do I need to provide to specify a custom silicon nitride liquid level probe?
   A: For a custom silicon nitride liquid level probe, you should provide the furnace or launder drawing, required overall length and immersion depth, probe diameter, flange or thread details, and the type of level control system or electrical interface in use.
5. Q: Is a silicon nitride liquid level probe suitable for alloys other than aluminium?
   A: The probe is primarily optimised for molten aluminium and aluminium alloys but can also be considered for certain non-ferrous metals after reviewing the alloy composition and operating temperature with the supplier.
6. Q: What is the maximum operating temperature for a silicon nitride liquid level probe?
   A: The ceramic body can withstand molten aluminium temperatures in the typical range of about 650–800°C and short excursions above that range if heating and cooling rates are controlled within recommended limits.

Silicon Nitride Liquid Level Probe Reviews

• ⭐️⭐️⭐️⭐️⭐️
  We introduced silicon nitride liquid level probes on two dosing furnaces to stabilise molten aluminium level. The probes have run through several months of production with fewer interruptions, and we now schedule replacements during planned maintenance instead of reacting to sudden sensor failures.
  -- Mark Petersen, Maintenance Manager, Northline Aluminum Die Casting
• ⭐️⭐️⭐️⭐️⭐️
  The custom silicon nitride liquid level probe we ordered matched our low pressure die casting furnace layout closely. The consistent level control has helped us cut back on level-related casting defects and made start-up and changeover more predictable.
  -- Laura Kim, Process Engineer, EuroCast Automotive Components
• ⭐️⭐️⭐️⭐️⭐️
  Working with ADCERAX as a factory supplier for silicon nitride liquid level probes gave us more flexibility on lengths and flange designs. Pricing is competitive for project quantities, and we can align deliveries with furnace overhaul schedules without over-stocking.
  -- Diego Alvarez, Purchasing Manager, ADCERAX Customer – Foundry Division
• ⭐️⭐️⭐️⭐️⭐️
  We use ADCERAX as one of our OEM sources for silicon nitride liquid level probes in our aluminium holding furnaces. The dimensional consistency and repeatable electrical characteristics simplify commissioning for our customers, especially on multi-furnace installations.
  -- Sophie Wagner, Technical Director, AlloyFlow Furnace Systems