Silicon carbide bricks are mainly composed of silicon carbide, along with auxiliary materials such as clay, corundum, and silica fume, and a special high-temperature binder. The forming process must balance "high density, high density uniformity, and structural integrity" - ensuring uniform density throughout the green body, achieving the required compressive strength of the finished product, a reasonable pore distribution with small pore diameters, while avoiding the breakage of silicon carbide particles and the formation of microcracks in the green body during the pressing process, and preventing local porosity caused by the agglomeration of the mixture. Currently, the technical limitations of traditional forming equipment have led to common problems in the production of silicon carbide bricks, such as uneven density, green body cracking, low product qualification rate, and unstable batch quality, which seriously restrict the industrial development of high-end silicon carbide bricks. Zhengzhou Haloong, relying on the third-generation permanent magnet synchronous servo direct drive core technology, has upgraded the HLDS series of CNC servo screw presses, specifically addressing the pain points in the forming of silicon carbide bricks and creating dedicated forming equipment. With the core advantages of precise pressure control, flexible pressure transmission, and intelligent adaptability, it has established a quality benchmark for high-end silicon carbide bricks.

Compared to ordinary refractory bricks, the forming of silicon carbide bricks is significantly more challenging. The silicon carbide particles in the raw materials are hard, angular, and have poor density uniformity. Moreover, the mixture has poor fluidity, a wide particle size distribution, and is prone to agglomeration. The requirements for the accuracy of the applied pressure, the pressing speed, and the holding time are extremely high - it is necessary to achieve the densification of the green body through precise pressing, ensuring that the compressive strength of the finished product is ≥ 60MPa and the volume density is controlled between 2.6-3.0g/cm³, while avoiding the breakage of silicon carbide particles and the formation of microcracks in the green body due to rigid impact, and precisely controlling the pore distribution to break up the agglomeration of raw materials and ensure the thermal shock resistance and wear resistance of the product.

Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic, and industry upgrade demands of silicon carbide bricks. With the core technology of permanent magnet synchronous servo motor direct drive + static pressure flexible pressure transmission + intelligent CNC system, it has specifically optimized the HLDS series of servo screw presses, comprehensively upgrading the equipment's precision, stability, and adaptability, precisely matching the forming requirements of silicon carbide bricks, and becoming the preferred equipment for the mass production of high-quality silicon carbide bricks, assisting refractory material enterprises in creating high-quality products suitable for high-temperature applications.

Equipped with a permanent magnet synchronous servo motor direct drive system, it completely eliminates the inefficient transmission structures such as traditional friction discs and clutches, with an extremely short transmission chain and zero energy loss in energy transmission. The equipment is equipped with a Haloong self-developed CNC pressure control module dedicated to silicon carbide bricks, which can digitally and precisely set the impact energy, pressing speed, stepwise pressing times, and holding time. The energy repetition control accuracy is ≤ ±1%, ensuring that the pressure in each forming process is highly consistent, completely eliminating the quality deviations caused by manual operation and mechanical fluctuations. In response to the poor fluidity, easy agglomeration, and hard particles of the silicon carbide mixture, a customized stepwise flexible pressing process is adopted. First, light pressure is applied to break up the agglomeration of raw materials and quickly expel the residual air inside the green body, then stepwise stable pressure is applied to compact the green body layer by layer, and finally, long-term holding pressure is applied to shape it. This ensures that all parts of the green body, including the center, edges, and corners, are uniformly stressed, with density fluctuations controlled within a very small range. This not only ensures the density of the green body but also avoids the breakage of silicon carbide particles, perfectly balancing the core advantages of high strength and thermal shock resistance of the product, and increasing the qualification rate of the finished product to over 99%.

It adopts a fully enclosed static pressure screw, nut, and dedicated heavy-duty bearing transmission structure. During operation, a stable high-pressure oil film is formed for protection, achieving flexible and uniform pressure transmission and completely avoiding the severe impact force and stress concentration problems caused by traditional rigid pressing. The pressurization process is smooth and gentle, with uniform and soft pressure transmission. It can not only fully expel the internal pores of the green body, disperse the agglomerated raw materials, and completely eliminate defects such as porosity, delamination, and cracks, but also protect the structure of silicon carbide particles gently, avoiding particle breakage and green body cracking. This significantly reduces the waste of high-cost raw materials and effectively extends the service life of the mold, lowering the cost of consumables and enhancing the production efficiency of the enterprise.

It breaks through the structural limitations of the fixed bottom dead center of traditional equipment and adopts a step-by-step forging forming mode. According to the material, size, and structural complexity (standard bricks, special-shaped bricks) of silicon carbide bricks, as well as the density requirements, it can flexibly adjust the stroke of the slider, the depth of pressurization, and the pressure intensity, precisely matching the forming needs of various silicon carbide bricks and covering the full range of production scenarios for high-end refractories. There is no need to worry about the deviation in raw material filling, the difference in silicon carbide particle size, or the uneven pressurization caused by raw material agglomeration. Combined with a rapid mold change system, the mold change is convenient and efficient, perfectly adapting to the flexible mode of multi-variety and batch production, meeting the batch supply needs of high-end fields.

The equipment is equipped with a dedicated forming parameter database for silicon carbide bricks, integrating the optimal forming process parameters for various specifications, different materials, and different density requirements of silicon carbide bricks, covering the forming parameters of common products such as ordinary dense type, high-strength wear-resistant type, and special-shaped silicon carbide bricks. Operators can retrieve them with one click, eliminating the need for repeated debugging and exploration, and significantly reducing the interference of human factors on product quality. All forming parameters can be permanently saved and reused in batches, ensuring that the density, compactness, and dimensional accuracy of each batch and each product are highly consistent, easily meeting the strict quality requirements of high-end fields at home and abroad, and helping enterprises smoothly open up the overseas high-end refractory market.

Compared with traditional friction presses, the Haloong servo screw press adopts an intelligent mode of on-demand start-stop and sleep energy saving. The servo motor only operates during the pressing process, and the standby state is completely zero energy consumption, with a comprehensive energy-saving rate of over 55%, significantly reducing the electricity cost of silicon carbide brick production and meeting the green and low-carbon development needs of the refractory industry. At the same time, the static pressure transmission structure has minimal wear, and is combined with a fully automatic forced lubrication system and an oil shortage alarm device, achieving maintenance-free operation, with a low failure rate and a service life far exceeding that of traditional equipment. The later maintenance cost is reduced by more than 40%, comprehensively compressing production, maintenance, and consumable costs, and helping enterprises achieve a green, low-carbon, and efficient profit-making production model.

The equipment is equipped with standardized industrial communication interfaces, which can be seamlessly linked with automatic and precise feeding machines, closed-loop distribution machines, intelligent demolding machines, non-destructive testing equipment for green bodies, and constant-temperature conveyor lines, building a fully automatic and intelligent forming production line for silicon carbide bricks, achieving unmanned control throughout the process from distribution, pressing, pressure holding, demolding to green body transfer and inspection, minimizing human intervention. This not only avoids damage to the green body caused by manual operation but also ensures forming accuracy and production efficiency. At the same time, it supports remote monitoring, parameter adjustment, fault warning, and production data traceability functions, allowing domestic and foreign customers to remotely and real-time control the production progress and product quality, fully conforming to the global refractory industry's trend of intelligent, digital, and green transformation, and helping enterprises build an intelligent production base for high-end silicon carbide bricks.

As a leading enterprise in the domestic electric servo screw press field, Zhengzhou Haloong Machinery Co., Ltd. has been focusing on the technological innovation of refractory forming equipment for 45 years, deeply exploring the forming process pain points of high-end refractories such as silicon carbide bricks, and insisting on empowering the refractory industry upgrade with customized technology. The Haloong HLDS series CNC servo screw press covers the full tonnage range from 200T to 1600T, and can provide one-to-one customized forming solutions based on the material, size, capacity, and density requirements of customers' silicon carbide bricks, fully meeting the mass production needs of various silicon carbide bricks and adapting to the supply of refractories in different high-end high-temperature fields.