The core competitiveness of zirconia spinel bricks lies in their uniform and dense microstructure and stable physical and chemical properties. The density and density uniformity of the green body are entirely dependent on precise control during the forming stage - the forming process must meet four core requirements: uniform density, dense structure, no cracks, and intact edges and corners. It is necessary to ensure uniform density throughout the green body, with the final product's bulk density controlled between 3.2-3.6g/cm³ and the apparent porosity ≤12%, laying a solid foundation for subsequent high-temperature sintering. At the same time, it is essential to prevent ZrO₂ particle agglomeration and raw material stratification during the pressing process to avoid defects such as loose structure, crack propagation, and spalling after sintering. Additionally, the pressing speed and holding time must be precisely controlled to accommodate the complex particle size distribution, poor air exhaust, and low fluidity of the zirconia spinel mixture, preventing residual pores within the green body that could lead to slag penetration and structural failure during high-temperature service. Currently, the technical limitations of traditional forming equipment have led to widespread issues in zirconia spinel brick production, including uneven density, green body cracking, edge and corner damage, large dimensional deviations, and low product qualification rates, severely hindering the industrialization of high-end zirconia spinel bricks. Zhengzhou Haloong, relying on the third-generation permanent magnet synchronous servo direct drive core technology, has optimized and upgraded the HLDS series of CNC servo screw presses, specifically addressing the forming challenges of zirconia spinel bricks and creating dedicated forming equipment. With the core advantages of precise pressure control, flexible pressure transmission, and intelligent adaptability, it has established a benchmark for high-end zirconia spinel brick quality.

Compared to ordinary refractory bricks, the forming of zirconia spinel bricks is significantly more challenging due to the characteristics of the raw materials and performance requirements. The mixture is composed of zirconia spinel coarse and fine powders, high-purity alumina, and zirconia additives in precise proportions. The particle size distribution is wide, the fluidity is poor, and air exhaust is difficult. Moreover, ZrO₂ particles are hard and brittle, making it easy for particle agglomeration, green body micro-cracks, and edge and corner damage to occur during the forming process. The precision requirements for the applied pressure, pressing speed, and holding time are extremely strict - it is necessary to achieve green body densification through precise pressing while ensuring uniform dispersion of ZrO₂ particles, and at the same time, avoid green body cracking and edge and corner damage caused by rigid impact. It is also necessary to efficiently remove air from the mixture to prevent residual pores from affecting the product's thermal shock resistance and slag erosion resistance.

Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic, and industry upgrade demands of zirconia spinel 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, precisely matching the forming requirements of zirconia spinel bricks. It has become the preferred equipment for mass production of high-quality zirconia spinel bricks, assisting refractory material enterprises in creating high-quality products suitable for high-temperature, strong erosion, and strong thermal shock conditions.

Equipped with a core permanent magnet synchronous servo motor direct drive system, it has completely eliminated 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 pressure output is stable and controllable throughout the process. The equipment is equipped with Haloong's independently developed zirconia spinel brick dedicated CNC pressure control module, 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 for each forming process is highly consistent, completely eliminating quality deviations caused by manual operation and mechanical fluctuations. In response to the complex particle size distribution, difficult exhaust, and easy agglomeration of zirconia alumina mixtures, a customized stepwise flexible pressurization process was developed. This process first lightly presses the raw materials to slowly expel the internal residual air, then gradually and steadily applies pressure layer by layer, and finally maintains a long-term pressure to shape the product. 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. At the same time, it effectively avoids the agglomeration of ZrO₂ particles and the stratification of raw materials, providing a solid foundation for the uniform combination of the bonding phase during subsequent high-temperature sintering, and increasing the product qualification rate to over 99%.

The equipment 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 application and gradual pressurization. This completely avoids the severe impact force and stress concentration problems caused 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 green body and disperse the agglomeration of ZrO₂ particles, completely eliminating defects such as porosity, stratification, and micro-cracks, but also gently protect the activity of ZrO₂ particles, avoiding green body cracking and edge damage, significantly reducing the waste of high-cost raw materials, and effectively extending the service life of the mold, reducing material costs, and improving the production efficiency of the enterprise.

Breaking through the structural limitation of the fixed lower dead point of traditional equipment, a stepwise forging forming mode is adopted. According to the material, size, and structural complexity (such as glass kiln lining bricks, continuous casting nozzle bricks, and special-shaped parts) of zirconia alumina bricks, as well as the density requirements, the stroke of the slider, the pressurization depth, and the applied pressure can be flexibly adjusted to precisely match the forming needs of various zirconia alumina 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, 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 alumina bricks, integrating the optimal forming process parameters for various specifications, different raw material ratios, and different density requirements of zirconia alumina bricks, including common products such as standard zirconia alumina bricks, special-shaped zirconia alumina bricks, and high-strength erosion-resistant zirconia alumina 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, and the ZrO₂ particle bonding phase is evenly distributed, 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 alumina 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 equipment 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 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 zirconia alumina bricks, achieving unmanned control throughout the process from distribution, pressing, pressure maintenance, 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. It supports remote monitoring, parameter adjustment, fault warning, and production data traceability functions, facilitating domestic and foreign customers to manage production progress and product quality in real time from different locations. It fully conforms to the global refractory industry's trend of intelligent, digital, and green transformation, and helps enterprises build an intelligent production base for high-end zirconia corundum bricks.

Zhengzhou Haloong Machinery Co., Ltd., as a leading enterprise in the domestic electric servo screw press field, has been focusing on technological innovation in refractory forming equipment for 45 years. It has been deeply engaged in solving the forming process pain points of high-end refractories such as zirconia corundum bricks, and has been committed to empowering the refractory industry's upgrading with customized technologies. The Haloong HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T. According to customers' requirements for zirconia corundum brick materials, specifications, production capacity, density, and raw material ratios, it can provide one-to-one customized forming solutions, fully meeting the mass production needs of various zirconia corundum bricks, and adapting to the supply of refractories in different high-end high-temperature, strong thermal shock, and strong erosion fields.