In the ceramic manufacturing process, the deformation of products during firing has always been a headache for manufacturers. This article delves into how composite corundum - mullite trays can effectively control ceramic deformation through structural optimization and improved installation methods, and explores their application value in the ceramic industry.
Composite corundum - mullite materials are known for their excellent stability at high temperatures. Compared with traditional ceramic trays, they have a lower thermal expansion coefficient. For example, traditional trays may have a thermal expansion coefficient of about 5 - 7×10⁻⁶/°C, while composite corundum - mullite trays can be controlled at around 3 - 4×10⁻⁶/°C. This means that in the high - temperature environment of the kiln (usually around 1200 - 1400°C), composite corundum - mullite trays are less likely to deform, ensuring the stability of the firing process.
Geometric shape optimization of the tray, such as the layout of grooves and the design of thickness gradients, can significantly improve the heat transfer path. Grooves on the tray surface can increase the contact area between the tray and the air in the kiln, promoting heat exchange. A well - designed thickness gradient can ensure that heat is evenly distributed across the tray. For instance, by reducing the thickness at the edge of the tray, heat can be transferred more quickly to the center, reducing the temperature difference between the edge and the center of the tray. According to experimental data, with optimized geometric shapes, the temperature difference across the tray can be reduced from about 30 - 40°C to less than 15°C, effectively reducing the warping and cracking rate of ceramic products.
The installation method of the tray, including the design of positioning holes and the stacking spacing, also has a significant impact on heat transfer. Properly designed positioning holes can ensure that the tray is accurately placed on the kiln car, avoiding uneven heat transfer caused by misalignment. The stacking spacing of trays affects the air circulation between trays. If the spacing is too small, the air flow will be blocked, resulting in uneven heat distribution. By optimizing the stacking spacing, the heat transfer efficiency can be improved. For example, increasing the stacking spacing from 20mm to 30mm can increase the heat transfer efficiency by about 15 - 20%.
Let's take a ceramic factory as an example. Before using our optimized composite corundum - mullite trays, the deformation rate of their ceramic products was about 25%. After adopting our trays with optimized structure and installation methods, the deformation rate dropped to less than 10%, a reduction of more than 60%. At the same time, the finished product rate increased from about 70% to over 90%. This shows that our trays can effectively solve the problem of ceramic deformation during firing.
Technical personnel often use on - site detection means such as infrared temperature measurement and deformation measurement. Infrared temperature measurement can quickly detect the temperature distribution on the tray surface, helping to identify areas with abnormal temperature. Deformation measurement can accurately measure the deformation of ceramic products and trays. Through these detection methods, problems can be found in time and corresponding adjustment measures can be taken.
Our trays have helped over 50 ceramic factories reduce the deformation rate by more than 30%. If you are also troubled by the problem of ceramic deformation during firing, don't miss this opportunity. Click here to learn more about our composite corundum - mullite trays and take the first step towards improving your ceramic production efficiency!
