Zirconia bricks, as a core category of high-end special refractory materials, are widely used in metallurgical continuous casting, glass melting furnaces, sintering of new energy lithium battery materials, high-end ceramic preparation, and high-temperature working conditions in aerospace due to their outstanding properties such as super high-temperature resistance, thermal shock resistance, chemical erosion resistance, and wear resistance. The service life and stability of zirconia bricks in the terminal application are not determined by the later sintering process, but rather by the uniformity and density of the green body during the forming process. Zirconia powder has strong agglomeration, poor fluidity, and is difficult to exhaust during forming. The requirements for the forming equipment's pressure application accuracy, pressure transmission softness, and process adaptability are far beyond those of ordinary refractory bricks. Ordinary forming equipment is prone to problems such as large density deviations, numerous micro-cracks, edge and corner damage, and excessive porosity in the green body, which seriously restricts the mass production yield of high-end zirconia bricks. Zhengzhou Haloong Machinery Co., Ltd. has been deeply engaged in the research and development and manufacturing of refractory material forming equipment for 46 years. It has specifically adapted to the forming process of zirconia bricks and crafted a dedicated servo screw press for zirconia bricks. With the core hard technology of servo direct drive, it precisely solves the forming problems of high-end zirconia bricks, laying a solid equipment foundation for domestic and foreign refractory material enterprises to mass-produce high-quality zirconia bricks.

To achieve long-term stable service in high-temperature working conditions, high-end zirconia bricks must meet four core requirements: uniform density throughout the green body, dense internal structure without defects, uniform size accuracy standards, and intact powder activity. The forming and pressing process, as a key pre-production step for zirconia bricks, directly determines the apparent porosity, bulk density, thermal shock resistance, and structural stability of the finished product. The comprehensive performance of the forming equipment directly affects the product's market competitiveness. In the face of the complex material characteristics of zirconia powder, the high difficulty of forming multi-specification and irregular-shaped bricks, and the strict quality requirements of high-end customers, the traditional coarse friction pressure machine and ordinary hydraulic press are completely unable to meet the production needs. Only dedicated high-precision, flexible, and intelligent forming equipment can achieve standardized, high-quality, and efficient mass production of zirconia bricks. Zhengzhou Haloong focuses on the high-end refractory material niche market, optimizing the structure and control system of the servo screw press, and tailoring a dedicated forming solution for the forming conditions of zirconia bricks, controlling the quality of the green body from the source.

The Haloong servo screw press is equipped with a third-generation permanent magnet synchronous servo direct drive core system, discarding the traditional and outdated friction transmission structure. Energy transmission is lossless, and pressure output is precisely controllable, with extremely small errors in the repeated control accuracy of the forming energy. The equipment is equipped with a dedicated numerical control system for zirconia bricks, allowing digital setting of the pressing speed, step-by-step pressing times, holding time, and forming pressure according to needs. It adapts to the characteristics of zirconia powder being slow to exhaust and prone to agglomeration, achieving a step-by-step flexible forming process of light pressing for slow exhaust, layer-by-layer stable pressure compaction, and finally precise pressure holding for shaping. It effectively breaks up the agglomerated structure of the powder, exhausts the residual air inside the green body, ensuring uniform density throughout the center, edges, and corners of the zirconia brick green body, with no density deviation in the same batch of products, and stable porosity of the finished product, fundamentally eliminating problems such as sintering cracking, high-temperature spalling, and shortened service life caused by density inhomogeneity. The product yield rate has significantly increased.

In response to the characteristics of high raw material costs, high brittleness, and poor impact resistance of zirconia bricks, the equipment adopts a fully enclosed static pressure screw nut transmission structure. During the entire forming process, a stable oil film is formed for protection, achieving flexible and uniform force transmission, completely eliminating the drawbacks of rigid impact pressure application in traditional equipment. The pressing process is smooth and gentle, without sudden stress concentration, ensuring the green body is fully compacted and dense while effectively avoiding problems such as micro-cracks, delamination, and edge and corner damage, reducing the waste of expensive zirconia raw materials, and simultaneously reducing the impact wear on the mold, extending the mold's service life, and truly achieving cost reduction and efficiency improvement for enterprises. The entire forming process protects the original activity of zirconia powder and does not damage the microstructure of the material, ensuring the formation of stable crystal phases during subsequent sintering and enhancing the high-temperature resistance and corrosion resistance of the finished products.

The equipment breaks through the structural limitations of traditional forming equipment with a fixed bottom dead center and adopts an intelligent step-by-step forging forming mode. It can flexibly and precisely adjust the slider stroke, pressing depth and forming force according to different material ratios, different specifications and sizes, and different structural shapes of zirconia bricks (standard lining bricks, continuous casting nozzle bricks, special-shaped structural parts, new energy-specific zirconia products, etc.). There is no need to frequently modify the main structure of the equipment. With a quick mold change configuration, the mold change is convenient and efficient, perfectly adapting to the production mode of multiple varieties, small batches and customized zirconia bricks. One machine can meet the production needs of all types of high-end zirconia bricks for enterprises, maximizing the equipment's versatility and production flexibility.

The equipment is equipped with a dedicated zirconia brick forming process database from Haloong, which includes the optimal forming parameters for various mainstream zirconia bricks. The parameters can be permanently saved, retrieved with one click and reused in batches. There is no need to rely on the manual experience of skilled workers to repeatedly adjust the parameters. Novices can operate simply and stably to achieve mass production, completely eliminating the quality fluctuations caused by human operation. It ensures that the forming accuracy, density and size specifications of each batch of zirconia bricks are highly consistent, helping enterprises achieve standardized and regulated production and easily meet the quality inspection requirements of high-end customers at home and abroad, smoothly opening up high-end refractory markets at home and abroad.

The equipment adopts a servo motor on-demand start-stop intelligent working mode, which only operates during the pressing process. There is zero energy consumption during the feeding, demolding and standby stages. Compared with traditional friction presses, the comprehensive energy-saving rate exceeds 55%, significantly reducing the enterprise's production electricity costs. The static pressure transmission structure has extremely low wear, and is equipped with a fully automatic forced lubrication and oil shortage alarm device. The equipment has a low failure rate, a long service life, and simple and convenient later maintenance and operation. The maintenance and spare parts replacement costs are greatly reduced, which is in line with the green, low-carbon and energy-efficient development trend of the refractory industry, and takes into account high-quality production and low-cost operation.

The equipment reserves standard industrial communication interfaces and can be seamlessly connected with automatic feeding, precise material distribution, intelligent demolding, blank detection, automatic transfer and other equipment to build a fully automatic and intelligent zirconia brick forming production line, achieving unmanned control throughout the process. It supports remote production monitoring, remote parameter adjustment, full traceability of production data and intelligent fault warning, digitally controlling the entire production process. This not only reduces the impact of manual intervention on the quality of the blanks, but also significantly improves production efficiency, adapting to the intelligent and digital transformation trend of the global refractory industry.

Zhengzhou Haloong Machinery has been dedicated to the research and development and manufacturing of servo screw presses for 45 years, deeply engaged in the high-end refractory forming niche field. It always takes the production needs of customers as the core and technological innovation as the driving force, continuously optimizing the performance of zirconia brick-specific forming equipment. The company's full-tonnage servo screw presses can be customized according to needs, adapting to different production capacities, specifications and quality requirements of zirconia bricks. The products are sold to more than 50 countries and regions around the world and have been recognized and trusted by refractory enterprises at home and abroad.