The core competitiveness of zirconia-mullite bricks lies in their uniform microstructure and stable composite crystal phase. The uniform distribution of crystal phases and the density of the body are entirely dependent on the precise control during the forming stage. The forming process must meet four core requirements: uniform density, dense structure, no delamination, and precise dimensions. It is necessary to ensure uniform density throughout the body, with the finished product's volume density controlled at 2.6-2.9g/cm³ and the apparent porosity ≤18%, laying the foundation for the uniform combination of zirconia and mullite crystal phases. At the same time, it is necessary to avoid delamination and agglomeration of raw materials during the pressurization process and prevent defects such as crystal phase segregation, loose structure, and peeling after sintering. Additionally, the pressurization speed and holding time must be precisely controlled to adapt to the complex particle size distribution and difficult exhaust of zirconia-mullite mixed materials, avoiding residual pores in the body that could lead to erosion and penetration during high-temperature service. Currently, the technical shortcomings of traditional forming equipment have led to common problems in the production of zirconia-mullite bricks, such as uneven density, delamination of the body, uneven dispersion of zirconia, large dimensional deviations, and low product qualification rates, seriously restricting the industrialization of high-end zirconia-mullite 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 forming pain points of zirconia-mullite bricks and creating dedicated forming equipment. With the core advantages of precise pressure control, flexible pressure transmission, and intelligent adaptation, it has established a quality benchmark for high-end zirconia-mullite bricks.

Compared to ordinary refractory bricks, the forming difficulty of zirconia-mullite bricks is significantly increased due to the composite characteristics of the raw materials. The mixed materials are composed of mullite coarse powder, fine powder, and zirconia micro powder in precise proportions, with a large particle size distribution range, poor fluidity, and difficult exhaust. Moreover, the density difference between zirconia and mullite raw materials is relatively large, making delamination and agglomeration extremely likely during the forming process. The requirements for the accuracy of the applied pressure, pressurization speed, and holding time are extremely strict. It is necessary to achieve densification of the body through precise pressurization and ensure the uniform dispersion of zirconia, while avoiding delamination and cracking of the body due to rigid impact. At the same time, it is necessary to efficiently remove the air in the mixed materials to prevent residual pores from affecting the product's erosion resistance.

Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic, and industry upgrade demands of zirconia-mullite 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. The equipment's precision, stability, and adaptability have been comprehensively upgraded, with advantages precisely matching the forming requirements of zirconia-mullite bricks. It has become the preferred equipment for mass production of high-quality zirconia-mullite bricks, assisting refractory material enterprises in creating high-quality products suitable for high-temperature and strong erosion conditions.

Equipped with a core permanent magnet synchronous servo motor direct drive system, it has completely eliminated traditional low-efficiency transmission structures such as friction discs and clutches. The transmission chain is extremely short, with zero energy loss in energy transmission, and the pressure output is stable and controllable throughout the process. The equipment is equipped with a zirconia-mullite brick-specific CNC pressure control module independently developed by Haloong, which can digitally and precisely set the impact energy, pressurization speed, stepwise pressurization times, and holding time. The energy repetition control accuracy is ≤±1%, ensuring that the forming pressure is highly consistent in each process, completely eliminating quality deviations caused by manual operation and mechanical fluctuations. In response to the complex particle size distribution, difficult exhaust, and easy delamination and agglomeration of zirconia-mullite mixed materials, a customized stepwise flexible pressurization process has been developed. It first lightly presses the loose raw materials and slowly expels the internal residual air, then gradually and steadily pressurizes and compacts layer by layer, and finally maintains long-term pressure for shaping. This ensures uniform force application in all parts of the body, including the center, edges, and corners, with density fluctuations controlled within a very small range. At the same time, it effectively avoids zirconia agglomeration and raw material delamination, providing a solid foundation for the uniform combination of composite crystal phases during subsequent high-temperature sintering, and the product qualification rate is increased to over 99%. The equipment adopts a fully enclosed static pressure screw, nut and special heavy-duty bearing transmission structure. During operation, a stable high-pressure oil film is formed for protection, achieving flexible and uniform force application and pressure relief, completely avoiding the severe impact force and stress concentration problems brought by traditional rigid pressurization. The pressurization process is smooth and gentle, with uniform and soft pressure transmission. It can not only fully expel the internal pores of the blank, disperse the agglomerated zirconia, and completely eliminate defects such as porosity, delamination, and cracks, but also gently protect the activity of mullite and zirconia particles, prevent delamination and cracking of the blank, significantly reduce the waste of high-cost raw materials, and effectively extend the service life of the mold, reduce material costs, and improve the production efficiency of the enterprise.

It breaks through the structural limitation of the fixed bottom dead center of traditional equipment and adopts a step-by-step forging forming mode. According to the material, size, structural complexity (standard brick, special-shaped brick, furnace lining brick, nozzle brick), and density requirements of zirconia mullite bricks, the stroke of the slider, the depth of pressurization, and the applied pressure can be flexibly adjusted to precisely match the forming requirements of various zirconia mullite bricks, covering the full range of production scenarios for high-end refractories. There is no need to worry about the problems of uneven pressurization caused by deviations in raw material filling volume, differences in particle size distribution, and changes in the fluidity of the mixture. Combined with a rapid mold changing system, mold changing 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 zirconia mullite bricks, integrating the optimal forming process parameters for various specifications, different raw material ratios, and different density requirements of zirconia mullite bricks, covering the forming parameters of common products such as ordinary standard bricks, special-shaped bricks, and high-strength erosion-resistant zirconia mullite products. Operators can retrieve them with one click, eliminating the need for repeated debugging and exploration, 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, with uniform dispersion of zirconia, 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 on-demand start-stop and sleep energy-saving intelligent mode. 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 zirconia mullite brick production, meeting the green and low-carbon development needs of the refractory industry. At the same time, the static pressure transmission structure has minimal wear, 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, reducing the later maintenance cost by more than 40%, comprehensively compressing production, maintenance, and material 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 blanks, and constant-temperature conveyor lines, building a fully automatic and intelligent forming production line for zirconia mullite bricks, achieving unmanned control throughout the process from distribution, pressing, pressure holding, demolding to blank transfer and inspection, minimizing human intervention. It not only avoids damage to the blank 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, facilitating real-time control of production progress and product quality by domestic and foreign customers from a distance, fully in line with the global refractory industry's trend of intelligent, digital, and green transformation, helping enterprises build an intelligent production base for high-end zirconia mullite bricks.

Zhengzhou Haloong Machinery Co., Ltd. is a leading enterprise in the domestic electric servo screw press field. For 45 years, it has always focused on technological innovation in refractory forming equipment, delved into the forming process pain points of high-end refractories such as zirconia mullite bricks, and insisted on empowering the refractory industry upgrade with customized technology. The Haloong HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T. According to the customer's requirements for zircon mullite brick material, specifications, production capacity, density and raw material ratio, we can provide one-to-one customized forming solutions, fully meeting the mass production needs of various zircon mullite bricks and products, and are suitable for the supply of refractory materials in different high-temperature and highly corrosive fields.