Solid sialon refractory is different from traditional common refractory bricks, high alumina bricks, and magnesia refractory. The forming process has extremely high technical requirements. The core production logic is that the density of the formed green body must be uniform and stable throughout to ensure the continuous and dense distribution of the sialon bonding phase after sintering, unlocking the core properties of high strength, corrosion resistance, high temperature resistance, and shock resistance of the product. Unlike the conventional refractory materials that can be formed by a rough process, the forming of solid sialon refractory has almost strict requirements for pressure accuracy, pressure application mode, pressure transmission softness, and process adaptability. Traditional friction presses and ordinary hydraulic presses are fundamentally unable to meet the specific production needs, and the industry's mass production pain points are prominent.

From the perspective of raw material characteristics, solid sialon refractory uses a variety of ultra-fine composite powders such as silicon nitride, alumina, aluminum powder, and silicon powder in a specific ratio. The powder has a large specific surface area, complex particle size distribution, and poor fluidity, making the exhaust resistance during forming very high. It is prone to internal gas entrapment and uneven local powder compaction. From the perspective of the forming process, the sialon green body cannot withstand strong impact pressure. Instant violent pressure application will directly tear the powder bonding interface, generating microscopic internal cracks that are invisible to the naked eye. These cracks will rapidly expand and spread during high-temperature use, causing premature failure of the product. From the perspective of quality control, sialon products are mostly used in high-end industrial core conditions. The density deviation and dimensional error of the same batch of green bodies must be controlled within a very small range. Traditional equipment relies on manual operation, has large pressure fluctuations, and the forming parameters cannot be solidified, resulting in inconsistent batch quality and a long-term low qualified product rate, making it difficult to deliver high-end orders. Under multiple strict requirements, the industry urgently needs a dedicated forming pressure equipment specifically designed for solid sialon refractory, which is precise, controllable, stable, and durable.

Relying on 45 years of specialized research and development in refractory pressure machines, Zhengzhou Haloong focuses on the dedicated forming process of solid sialon refractory, innovatively developing a three-in-one core technology of permanent magnet synchronous servo direct drive, static pressure flexible pressure transmission, and dedicated intelligent numerical control system for sialon. It has upgraded the HLDS series of servo screw presses, eliminating the structural defects of traditional equipment. With the core advantages of precision, flexibility, intelligence, and energy conservation, it fully meets the high-quality forming requirements of solid sialon refractory and has become the standard forming equipment for high-end mass production of sialon refractory worldwide.

The equipment is equipped with Haloong's exclusive permanent magnet synchronous servo direct drive system, completely eliminating inefficient and easily damaged transmission components such as traditional friction discs and clutches. The transmission chain is short, and energy transmission is loss-free. The repeatability accuracy of the forming impact energy and pressure output is ≤±1%, and the entire process is digitally precise and controllable. In response to the characteristics of sialon ultra-fine composite powder being difficult to exhaust and compact, it can be set with a dedicated process of step-by-step staged pressure application, light pressure exhaust, stable pressure compaction, and long-term pressure holding. First, it applies low-speed light pressure to slowly exhaust the residual air inside the green body, eliminating the defect of gas entrapment and porosity. Then, it applies staged uniform pressure to compact layer by layer, ensuring that all types of sialon powders are evenly distributed and combined, and the density of the green body is highly consistent from the center to the corners, with the density variation coefficient strictly controlled within an industry ultra-low standard. After sintering, the sialon bonding phase is continuously and densely distributed, and the high-temperature strength, corrosion resistance, and thermal shock resistance of the product are fully met and stable in batches.

It adopts a fully enclosed static pressure screw and nut heavy-duty transmission structure, forming a stable high-pressure oil film buffer protection layer during operation, achieving flexible and uniform pressure application. It completely eliminates the strong impact of traditional equipment. The pressure application process is smooth and gentle, evenly distributing the force. It can fully compact the sialon green body, disperse powder agglomeration, and eliminate layering and porosity problems, without damaging the powder bonding structure or causing internal stress concentration. It fundamentally eliminates quality defects such as micro-cracks, corner damage, and layering and cracking of the green body. It not only significantly reduces the waste and loss of high-value sialon raw materials but also effectively extends the service life of the mold, reducing production costs in both directions. Breaking through the structural limitations of the fixed bottom dead center of traditional forming equipment, it adopts an intelligent progressive forging forming mode. According to the specifications and dimensions, powder ratio, forming density requirements, and complexity of the special-shaped structure of different sialon products, it can flexibly and precisely adjust the slider stroke, pressing depth and forming force. Whether it is standard sialon refractory bricks or special-shaped kiln mouth components and special wear-resistant prefabricated parts, they can be quickly adapted for forming without the need for repeated machine adjustments. Combined with a rapid mold change structure, it enables convenient and efficient production changes, perfectly meeting the flexible production needs of enterprises for multiple varieties, small batches, and high quality. It helps enterprises quickly expand their high-end sialon refractory product lines.

The equipment is equipped with a custom sialon bonding refractory material exclusive forming process database by Haloong, integrating the optimal forming parameters for sialon products of different ratios, specifications, and application conditions. All process data can be permanently saved, retrieved with one click, and reused in batches. There is no need to rely on the experience of skilled operators for debugging. Novices can also quickly start mass production, completely eliminating quality deviations caused by human operation. The entire forming data can be recorded in real time and traced for query, perfectly meeting the quality control and qualification review requirements of domestic and foreign high-end customers, helping enterprises smoothly open up high-end sialon refractory markets at home and abroad.

It adopts a servo motor on-demand start-stop intelligent energy-saving mode, operating only during the pressing forming process. The motor is in sleep mode with zero energy consumption during the feeding, demolding, and standby stages. The comprehensive energy-saving rate is over 55% compared to traditional equipment, significantly reducing the enterprise's production electricity costs. The static pressure transmission structure has extremely low wear, combined with a fully automatic intelligent forced lubrication system and an oil shortage automatic alarm device, resulting in a very low equipment failure rate and a long maintenance-free period, directly reducing the later operation and maintenance costs by over 40%. The entire process operates with low noise and low vibration, meeting the industrial green production standards and stabilizing the production conditions, helping enterprises achieve the dual goals of cost reduction and efficiency improvement as well as green compliance.

The equipment is equipped with standardized industrial intelligent communication interfaces, which can be seamlessly connected with automatic precise feeding machines, intelligent material distribution machines, automatic demolding equipment, and non-destructive testing equipment for green bodies, building a fully automatic intelligent sialon refractory forming production line. It realizes unmanned control throughout the entire process from material distribution, pressing, holding pressure, demolding to green body transfer and quality inspection. It minimizes human intervention, avoids the impact of human operation on the forming accuracy of green bodies, and supports remote equipment monitoring, remote parameter debugging, intelligent fault warning, and digital management of production data, in line with the global refractory industry's trend of intelligent and digital transformation. It helps enterprises build an intelligent benchmark production base for high-end sialon refractory materials.

Zhengzhou Haloong Machinery Co., Ltd. has always been committed to the technological innovation of high-end refractory forming equipment. With 45 years of experience in the research and development, design, manufacturing, and customized services of pressure machines, it has always kept pace with the high-end, green, and intelligent development needs of the global sialon bonded refractory industry. With the HLDS series servo screw press as the core, it provides one-to-one exclusive forming overall solutions for sialon products to domestic and foreign refractory enterprises. The equipment tonnage covers the full range from 200T to 1600T, and can be customized with exclusive configurations to meet the mass production forming needs of various sialon bonded refractory materials.