What are the main production processes of high alumina ceramic balls?
What are the main production processes of high alumina ceramic balls?
The main production process of high-alumina ceramic balls is as follows:
Raw material preparation
1. Raw material selection: Select high-grade alumina powder as the main raw material, usually requiring high alumina content, high purity and low impurity content. Sometimes trace amounts of rare earth metal oxides and other additives are added, such as titanium dioxide (TiO₂) as a mineralizer.
2. Pretreatment: Screen and remove impurities from the raw materials to ensure that the purity and particle size of the raw materials meet the requirements. For block raw materials, crushing, grinding and other operations are required to achieve the required particle size, such as grinding the raw materials into fine powder by a ball mill.
Molding process
1. Plastic molding: The mud material that has been processed by batching, ball milling, etc. is kneaded by a vacuum mud kneading machine to make the mud material have good plasticity. Then the mud material is made into a ball by extrusion molding or manual kneading. For example, a hydraulic extruder is used to extrude mud strips, and then cut into mud segments according to the specifications of the pellets, and manually or mechanically kneaded into pellets.
-Dry pressing: Put the powder with a certain particle size and fluidity obtained by spray drying into a mold and shape it under a certain pressure. It is often used to produce high-aluminum ceramic balls with large size and regular shape.
2. Isostatic pressing
Wet pack cold isostatic pressing: Put the powder into a soft mold with a spherical inner cavity (such as a rubber mold), seal it and put it into the working cylinder of the cold isostatic press, introduce high-pressure liquid medium, so that the soft mold and powder are subjected to equal pressure in all directions and are evenly compressed. After unloading the pressure, take out the soft mold and the internal blank. The blank formed by this method has high density and good uniformity.
Dry isostatic pressing: Put the powder into a special mold, put it into the isostatic press, and apply uniform pressure through the gas medium to shape the powder. It is easy to realize automated production, and the shape and appearance of the blank are consistent, but the molding performance requirements of the powder are high.
Drying process
Natural drying: The formed high-aluminum ceramic ball blank is dried in a natural environment to allow the water to evaporate naturally. This method is simple and low-cost, but the drying time is long and is greatly affected by the ambient humidity and temperature.
Hot air drying: Place the green body in a drying kiln or drying box and use hot air circulation to remove moisture. By controlling the drying temperature, humidity and ventilation conditions, the drying efficiency can be improved, the drying time can be shortened, and the drying quality can be guaranteed.
Microwave drying: Microwave energy is used to make the water molecules in the green body vibrate at high frequencies, thereby generating heat to evaporate the water quickly. Microwave drying has the advantages of fast drying speed, good uniformity, high thermal efficiency, and easy control, but the equipment investment cost is relatively high.
Sintering process
Ordinary sintering: The dried green body is placed in a high-temperature kiln for sintering, and natural gas, coal gas, etc. are generally used as fuel. According to the composition and performance requirements of the high-alumina porcelain ball, the appropriate sintering temperature and insulation time are determined. The sintering temperature is usually around 1500℃-1650℃, and the insulation time is 10-15 hours.
Atmosphere sintering: Sintering is carried out in a specific atmosphere (such as hydrogen, nitrogen, argon, etc.). Atmosphere sintering can improve the microstructure and properties of high-aluminum ceramic balls. For example, sintering in a reducing atmosphere can reduce the oxygen content in the ceramic balls and improve their electrical conductivity and thermal conductivity.
Hot pressing sintering: A certain amount of pressure is applied during the sintering process to densify the green body under the combined action of high temperature and pressure. Hot pressing sintering can significantly improve the density, strength and hardness of high-aluminum ceramic balls, but the equipment cost is high and the production efficiency is relatively low.
Post-processing process
Grinding and polishing: The sintered high-aluminum ceramic balls are ground and polished to improve their surface finish and dimensional accuracy to meet the needs of different application scenarios.
Detection and grading: Various detection equipment and methods are used to detect the appearance, size, density, strength, hardness and other properties of high-aluminum ceramic balls. The ceramic balls are graded according to the test results and unqualified products are eliminated.
Packaging and warehousing: The qualified high-aluminum ceramic balls are packaged, usually using packaging materials such as cartons and woven bags. The packaged products are stored in the warehouse and wait for shipment.
What are the main production processes of high alumina ceramic balls?
The main production process of high-alumina ceramic balls is as follows:
Raw material preparation
1. Raw material selection: Select high-grade alumina powder as the main raw material, usually requiring high alumina content, high purity and low impurity content. Sometimes trace amounts of rare earth metal oxides and other additives are added, such as titanium dioxide (TiO₂) as a mineralizer.
2. Pretreatment: Screen and remove impurities from the raw materials to ensure that the purity and particle size of the raw materials meet the requirements. For block raw materials, crushing, grinding and other operations are required to achieve the required particle size, such as grinding the raw materials into fine powder by a ball mill.
Molding process
1. Plastic molding: The mud material that has been processed by batching, ball milling, etc. is kneaded by a vacuum mud kneading machine to make the mud material have good plasticity. Then the mud material is made into a ball by extrusion molding or manual kneading. For example, a hydraulic extruder is used to extrude mud strips, and then cut into mud segments according to the specifications of the pellets, and manually or mechanically kneaded into pellets.
-Dry pressing: Put the powder with a certain particle size and fluidity obtained by spray drying into a mold and shape it under a certain pressure. It is often used to produce high-aluminum ceramic balls with large size and regular shape.
2. Isostatic pressing
Wet pack cold isostatic pressing: Put the powder into a soft mold with a spherical inner cavity (such as a rubber mold), seal it and put it into the working cylinder of the cold isostatic press, introduce high-pressure liquid medium, so that the soft mold and powder are subjected to equal pressure in all directions and are evenly compressed. After unloading the pressure, take out the soft mold and the internal blank. The blank formed by this method has high density and good uniformity.
Dry isostatic pressing: Put the powder into a special mold, put it into the isostatic press, and apply uniform pressure through the gas medium to shape the powder. It is easy to realize automated production, and the shape and appearance of the blank are consistent, but the molding performance requirements of the powder are high.
Drying process
Natural drying: The formed high-aluminum ceramic ball blank is dried in a natural environment to allow the water to evaporate naturally. This method is simple and low-cost, but the drying time is long and is greatly affected by the ambient humidity and temperature.
Hot air drying: Place the green body in a drying kiln or drying box and use hot air circulation to remove moisture. By controlling the drying temperature, humidity and ventilation conditions, the drying efficiency can be improved, the drying time can be shortened, and the drying quality can be guaranteed.
Microwave drying: Microwave energy is used to make the water molecules in the green body vibrate at high frequencies, thereby generating heat to evaporate the water quickly. Microwave drying has the advantages of fast drying speed, good uniformity, high thermal efficiency, and easy control, but the equipment investment cost is relatively high.
Sintering process
Ordinary sintering: The dried green body is placed in a high-temperature kiln for sintering, and natural gas, coal gas, etc. are generally used as fuel. According to the composition and performance requirements of the high-alumina porcelain ball, the appropriate sintering temperature and insulation time are determined. The sintering temperature is usually around 1500℃-1650℃, and the insulation time is 10-15 hours.
Atmosphere sintering: Sintering is carried out in a specific atmosphere (such as hydrogen, nitrogen, argon, etc.). Atmosphere sintering can improve the microstructure and properties of high-aluminum ceramic balls. For example, sintering in a reducing atmosphere can reduce the oxygen content in the ceramic balls and improve their electrical conductivity and thermal conductivity.
Hot pressing sintering: A certain amount of pressure is applied during the sintering process to densify the green body under the combined action of high temperature and pressure. Hot pressing sintering can significantly improve the density, strength and hardness of high-aluminum ceramic balls, but the equipment cost is high and the production efficiency is relatively low.
Post-processing process
Grinding and polishing: The sintered high-aluminum ceramic balls are ground and polished to improve their surface finish and dimensional accuracy to meet the needs of different application scenarios.
Detection and grading: Various detection equipment and methods are used to detect the appearance, size, density, strength, hardness and other properties of high-aluminum ceramic balls. The ceramic balls are graded according to the test results and unqualified products are eliminated.
Packaging and warehousing: The qualified high-aluminum ceramic balls are packaged, usually using packaging materials such as cartons and woven bags. The packaged products are stored in the warehouse and wait for shipment.
We warmly welcome new and regular customers to join us hand in hand and cooperate happily!
Copyright © 2024 Pingxiang Ksource Chemical Packing Co., Ltd.