The core competitiveness of Sialon bonded refractory materials lies in its uniform and dense microstructure and the synergistic effect of the two components. The density, density uniformity and component dispersion of the green body are completely dependent on the precise control during the forming stage - the forming process needs to meet six core requirements: uniform density, dense structure, no cracks, intact corners, uniform dispersion of the two components, and no damage to the activity of the particles. It is necessary to ensure that the density of the green body is uniform throughout, ensuring that the volume density of the finished product is controlled at 2.8-3.2g/cm³ and the apparent porosity is ≤13%, laying a solid foundation for subsequent high-temperature sintering. At the same time, it is necessary to avoid the agglomeration of Sialon particles and the stratification of silicon nitride and alumina components during the pressurization process to prevent structural porosity, crack propagation, and spalling after sintering. The pressurization speed and holding time must be precisely controlled to adapt to the complex particle size distribution, difficult exhaust, and uneven fluidity of the Sialon bonded refractory materials mixture, avoiding residual pores in the green body that could lead to structural failure during high-temperature service. It is also necessary to protect the activity of Sialon particles to avoid oxidation affecting the corrosion resistance and high-temperature resistance of the product. Moreover, it is necessary to precisely match the forming pressure requirements of different specifications of Sialon bonded refractory materials to avoid over-pressurization damage and under-pressurization porosity. Currently, the technical shortcomings of traditional forming equipment have led to common problems in the production of Sialon bonded refractory materials, such as uneven density, uneven component dispersion, green body cracking, corner damage, large dimensional deviations, and low product qualification rates, seriously restricting the industrialization of high-end Sialon bonded refractory materials. Zhengzhou Haloong, relying on the third-generation permanent magnet synchronous servo direct drive core technology, has optimized and upgraded the HLDS series CNC servo screw press, specifically addressing the forming pain points of Sialon bonded refractory materials, creating dedicated forming equipment. With the core advantages of precise pressure control, flexible pressure transmission, and intelligent matching, it has established a benchmark for high-end Sialon bonded refractory materials quality.

Compared with ordinary refractory bricks and single silicon nitride refractory materials, Sialon bonded refractory materials have a significantly increased forming difficulty due to their dual-component composite characteristics and complex particle size distribution. The mixture is composed of Sialon powder, silicon nitride powder, alumina powder, and sintering aids in precise proportions. The particle size distribution range is large, the specific surface area is uneven, the fluidity is significantly different, and the exhaust is difficult. Moreover, Sialon particles are hard, brittle, and prone to oxidation, making it easy to experience particle agglomeration, component stratification, micro-cracks in the green body, corner damage, and surface oxidation 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 green body densification through precise pressurization, ensuring the uniform dispersion of Sialon, silicon nitride, and alumina particles, while avoiding green body cracking and corner damage caused by rigid impact. At the same time, it is necessary to efficiently remove the air in the mixture to prevent residual pores from affecting the product's thermal shock resistance and corrosion resistance. It is also necessary to control the temperature fluctuations during the pressurization process to prevent the oxidation and deterioration of Sialon particles. Moreover, it is necessary to adapt to the differentiated forming requirements of different specifications and uses of Sialon bonded refractory materials.

Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic, and industry upgrade demands of Sialon bonded refractory materials. With the core technology of permanent magnet synchronous servo motor direct drive + static pressure flexible pressure transmission + intelligent numerical control system, it has specifically optimized the HLDS series servo screw press, comprehensively upgrading the equipment's precision, stability, and adaptability. The advantages precisely match the forming requirements of Sialon bonded refractory materials, making it the preferred equipment for the mass production of high-quality Sialon bonded refractory materials. It helps refractory material enterprises create high-quality products suitable for high-temperature, strong corrosion, and strong thermal shock conditions, seizing the opportunity in the high-end market.

Equipped with a core 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 during energy transmission. The pressure output is stable and controllable throughout the process. The equipment is equipped with a self-developed CNC pressure control module for Sialon bonded refractories by Haloong, which can digitally and precisely set the striking energy, pressurization speed, stepwise pressurization times, and pressure holding duration. The energy repetition control accuracy is ≤±1%, ensuring that the pressure for each molding is highly consistent, completely eliminating the quality deviations caused by manual operation and mechanical fluctuations. In response to the complex particle size distribution, difficult exhaust, easy agglomeration, and component stratification of Sialon bonded mixtures, a customized stepwise flexible pressurization process is adopted. It first lightly presses the raw materials to slowly expel the internal residual air, then gradually and steadily pressurizes layer by layer, and finally maintains the pressure for a long time to shape. This ensures that all parts of the blank, including the center, edges, and corners, are uniformly stressed, and the density fluctuation is controlled within a very small range. At the same time, it effectively avoids the agglomeration of Sialon particles, the stratification of silicon nitride and alumina components, and protects the activity of Sialon particles, providing a solid foundation for the uniform formation of solid solutions during subsequent high-temperature sintering. The qualified rate of finished products is increased 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 blank, disperse the agglomeration of Sialon particles, and completely eliminate defects such as porosity, stratification, and micro-cracks, but also gently protect the activity of Sialon particles, prevent the cracking and corner damage 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 stepwise forging molding mode. According to the material, size, structural complexity (irregular structural parts, nozzles, lining bricks), density requirements, and component ratios of Sialon bonded refractories, the stroke of the slider, pressurization depth, and pressurization force can be flexibly adjusted to precisely match the molding requirements of various Sialon bonded refractories, covering the full range of production scenarios for high-end composite 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 such as metallurgy and new energy.

The equipment is equipped with a dedicated forming parameter database for Sialon bonded refractories, integrating the optimal forming process parameters for various specifications, different raw material ratios, and different density requirements of Sialon bonded refractories. It covers the forming parameters of common products such as standard Sialon bonded bricks, irregular Sialon structural parts, and high-strength corrosion-resistant Sialon lining 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 Sialon, silicon nitride, and alumina particles are evenly dispersed, effectively avoiding particle oxidation, and easily meeting the strict quality requirements of high-end fields at home and abroad, helping enterprises smoothly open up the overseas high-end composite refractory market.

Compared with traditional friction presses, Haloong's 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%. This significantly reduces the electricity cost of Sialon bonded refractory production and meets 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. The equipment has a low failure rate and a service life far exceeding that of traditional equipment, reducing the later maintenance and operation costs by over 40%. It comprehensively compresses production, operation, and material costs, 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 integrated with automatic and precise feeding machines, closed-loop distribution machines, intelligent demolding machines, non-destructive testing equipment for green bodies, and constant-temperature conveying lines to build a fully automatic and intelligent forming production line for sialon-bonded refractories, achieving unmanned control throughout the entire process from distribution, pressing, pressure holding, demolding to green body transfer and inspection, minimizing human intervention. This not only avoids damage to the green bodies 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 domestic and foreign customers to remotely and in real-time control the production progress and product quality, fully aligning with the global refractory industry's trend of intelligent, digital, and green transformation, and assisting enterprises in building high-end sialon-bonded refractory intelligent production bases.

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, delving into the forming process pain points of high-end composite refractories such as sialon-bonded refractories, and adhering to the principle of empowering industrial upgrading with customized technology. The Haloong HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T, and can provide one-to-one customized forming solutions based on customers' requirements for sialon-bonded refractory materials, specifications, production capacity, density, and raw material ratios, fully meeting the mass production needs of various sialon-bonded refractories and adapting to the supply of refractories in different high-end high-temperature, strong thermal shock, and strong corrosion-resistant fields.