Selecting the Right Materials for Melt Pressure Transducers in High-Temperature, Abrasive, and Corrosive Environments

Melt pressure transducers operate in extreme processing conditions, where high temperatures, abrasive materials, and corrosive environments can severely impact their durability and performance. Selecting the correct materials for sensor construction is essential to ensure longevity, accuracy, and reliability. The NoNonSensors Technical Sales Team has developed this guide to help process engineers and maintenance professionals choose the best materials for their specific applications. (NNS always recommends consulting chemical and process engineers if they are main concerns in key processes)

Key Challenges in Material Selection

Melt pressure transducers must withstand:

1. High Temperatures – Prolonged exposure to extreme heat can cause material degradation and sensor failure.

2. Abrasive Materials – Reinforced polymers, filled resins, and additives can cause excessive wear on sensor diaphragms and housings.

3. Corrosive Environments – Certain polymers, gases, and cleaning agents can chemically

Material	Properties	Best Applications
Inconel	High-temperature resistance, corrosion-resistant	Ideal for extreme heat and aggressive chemical environments
Hastelloy	Exceptional chemical resistance, withstands oxidizing and reducing agents	Best for highly corrosive polymer processes and aggressive cleaning agents
Stainless Steel (17-4 PH, 316L)	Good corrosion resistance, moderate wear resistance	General-purpose applications, suitable for mild corrosive and abrasive materials
Tungsten Carbide Coatings	Superior wear resistance, high hardness	Recommended for abrasive polymers with fillers like glass or carbon fibers
Ceramic Coatings	High wear resistance, chemically inert	Useful in applications requiring extreme abrasion and corrosion resistance

 

Application-Specific Material Recommendations

1. High-Temperature Applications

• Use Inconel for transducer diaphragms and housings when processing high-temperature materials like PEEK, PPS, or fluoropolymers.

• Ensure electrical components are rated for extreme temperatures to prevent signal drift or failure.

2. Abrasive Polymer Processing

• Tungsten carbide or ceramic-coated diaphragms extend sensor life when processing glass-filled nylon, carbon-filled polymers, or other highly abrasive compounds.

• Hardened stainless steel (17-4 PH) provides moderate abrasion resistance for less demanding applications.

3. Corrosive Chemical Resistance

• Hastelloy is ideal for handling aggressive cleaning chemicals, acid-based polymers, and high-chlorine environments.

• 316L stainless steel is suitable for general chemical resistance but may degrade in highly aggressive conditions.

Best Practices for Maximizing Sensor Longevity

• Select the right sensor material based on operating conditions and polymer characteristics.

• Use protective coatings to enhance wear and corrosion resistance.

• Regularly inspect sensors for signs of wear or corrosion and replace as needed.

• Follow manufacturer cleaning guidelines to prevent material degradation over time.

Choosing the correct materials for melt pressure transducers ensures optimal performance and longevity in extreme processing environments. Whether dealing with high temperatures, abrasive materials, or corrosive chemicals, selecting Inconel, Hastelloy, tungsten carbide, or ceramic coatings can significantly extend sensor life and maintain accurate pressure measurements.

For expert guidance on selecting the best materials for your application, contact the NoNonSensors Technical Sales Team today.

www.NoNonSensors.com | sales@nononsensors.com