The core competitiveness of zirconia bricks lies in their uniform and dense microstructure and stable crystal phase composition. The density, density uniformity, and microstructure integrity of the green body are entirely dependent on precise control during the forming stage - the forming process must meet six core requirements: uniform density, dense structure, no cracks, intact edges and corners, undamaged powder activity, and precise dimensions. It is necessary to ensure uniform density throughout the green body, with the final product's volume density controlled between 5.6-6.0g/cm³ and the apparent porosity ≤10%, laying a solid foundation for subsequent high-temperature sintering. At the same time, it is essential to prevent the agglomeration of zirconia powder during the pressurization process to avoid defects such as loose structure, crack propagation, and spalling after sintering. Additionally, the pressurization speed and holding time must be precisely controlled to accommodate the poor fluidity and difficult exhaust of zirconia powder, avoiding internal residual pores in the green body that could lead to structural failure during high-temperature service. Moreover, the activity of zirconia powder must be protected to prevent oxidation and deterioration caused by temperature fluctuations during pressurization, which could affect the product's high-temperature resistance and corrosion resistance. Finally, the forming pressure requirements for different specifications and applications of zirconia bricks must be precisely matched to avoid over-pressurization damage and under-pressurization porosity. Currently, the technical shortcomings of traditional forming equipment have led to widespread problems in zirconia brick production, such as uneven density, green body cracking, edge and corner damage, large dimensional deviations, and low product qualification rates, severely restricting the industrialization of high-end zirconia 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 pain points of zirconia brick forming 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 brick quality.

Compared to ordinary refractory bricks, zirconia bricks have significantly increased forming difficulty due to their special powder characteristics and strict forming processes. Zirconia mixtures are composed of zirconia powder as the core, with a small amount of sintering aids. The powder has a large specific surface area and high surface energy, making it prone to agglomeration, with extremely poor fluidity and difficult exhaust. During the forming process, it is necessary to precisely control the applied pressure and speed to achieve densification of the green body while avoiding powder agglomeration and green body cracking. At the same time, the powder activity must be protected to prevent oxidation and deterioration. Moreover, zirconia bricks come in various specifications, from zirconia water mouth bricks for metallurgical continuous casting, zirconia lining bricks for glass melting furnaces, to zirconia structural components for new energy and high-end zirconia products for aerospace. The forming pressure, pressurization speed, and holding time for different types of products vary significantly, requiring extremely high process adaptability from the equipment.

Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic, and industry upgrade demands of zirconia 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. The advantages precisely match the forming requirements of zirconia bricks, making it the preferred equipment for mass production of high-quality zirconia bricks and assisting refractory material enterprises in creating 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 traditional low-efficiency transmission structures such as 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 Haloong's independently developed zirconia brick dedicated CNC pressure control module, 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 characteristics of zirconia powder, such as strong agglomeration, poor fluidity, and difficulty in exhaust, a customized stepwise flexible pressurization process has been developed. This process first lightly presses the raw materials to gradually expel the residual air inside, then steadily applies pressure layer by layer to compact the material, and finally maintains the pressure for a long time to shape the product. This ensures uniform force application to all parts of the green body, including the center, edges, and corners, with density fluctuations controlled within a very small range. It also effectively breaks up the agglomerated zirconia powder, protects the powder's activity, and prevents oxidation and deterioration, providing a solid foundation for the uniform formation of crystal phases during subsequent high-temperature sintering. The qualified product rate has been 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 green body and break up the agglomerated zirconia powder, completely eliminating defects such as porosity, delamination, and microcracks, but also gently protect the activity of the zirconia powder, prevent the green body from cracking and corner damage, 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.

Breaking through the structural limitations of the fixed bottom dead center of traditional equipment, a stepwise forging forming mode is adopted. According to the material, size, structural complexity (irregular structural parts, nozzles, lining bricks), density requirements, and raw material ratios of zirconia bricks, the stroke of the slider, the pressurization depth, and the applied pressure can be flexibly adjusted to precisely match the forming requirements of various zirconia bricks, covering the full range of production scenarios for high-end zirconia bricks. There is no need to worry about the problems of uneven pressurization caused by deviations in raw material filling, differences in powder particle size, and changes in the fluidity of the mixed material. 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 such as metallurgy, new energy, and aerospace.

The equipment is equipped with a dedicated zirconia brick forming parameter database, integrating the optimal forming process parameters for various specifications, different raw material ratios, and different density requirements of zirconia bricks, covering the forming parameters of common products such as standard zirconia bricks, irregular zirconia structural parts, and high-strength corrosion-resistant zirconia 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, porosity, and dimensional accuracy of each batch and each product are highly consistent, with uniform dispersion and intact activity of zirconia powder, easily meeting the strict quality requirements of high-end fields at home and abroad, and helping enterprises smoothly open up the overseas high-end zirconia brick 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%. This significantly reduces the electricity cost of zirconia 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, and is equipped 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 cost by more than 40%. It comprehensively compresses production, maintenance, 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 linked with automatic precise feeding machines, closed-loop distribution machines, intelligent demolding machines, green body non-destructive testing equipment, and constant temperature conveyor lines to build an automatic and intelligent zirconia brick forming production line. It realizes 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 debugging, fault early 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 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 refractory materials such as zirconia bricks and has been committed to empowering industrial upgrading with customized technology. Haloong's HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T. According to the customer's requirements for zirconia brick material, specifications, production capacity, density, and raw material ratio, it can provide one-to-one customized forming solutions, fully meeting the mass production needs of various zirconia bricks and adapting to the supply of refractories in different high-end high-temperature, strong thermal shock, and strong corrosion fields.