Are you frequently encountering the problem of mosaic collapse during firing? It's highly likely that the root cause lies in the insufficient thermal stability of the trays. In fact, about 90% of such issues can be attributed to this factor. This article will delve deep into how composite corundum - mullite trays can address high - temperature deformation, warping, and aging problems from the source. We'll also teach you how to quickly identify the usage status of trays, scientifically set replacement cycles, and provide selection suggestions and practical guidelines based on typical scenarios such as mosaics, sanitary ware, and roof tiles, helping you improve kiln yield and production efficiency.
The thermal stability of the tray material is a critical factor that directly impacts ceramic firing quality. When the tray lacks sufficient thermal stability, it is prone to high - temperature deformation, warping, and aging, which in turn lead to problems like mosaic collapse during firing. Let's take a closer look at how different materials perform under high - temperature conditions.
Among various tray materials, composite corundum - mullite trays stand out. They have excellent thermal stability, which can effectively resist deformation and warping at high temperatures. Compared with other common materials, their performance is significantly better in the temperature range of 1000°C - 1400°C, which is often encountered in ceramic firing processes.
Mosaics require high - precision firing. The trays used for mosaic firing need to have extremely high flatness and thermal stability. Any slight deformation of the tray can cause the mosaic to collapse during firing. Composite corundum - mullite trays can maintain their shape well in the high - temperature environment of mosaic firing, ensuring the quality of the final product.
Sanitary ware products are usually larger in size and have more complex shapes. The trays for sanitary ware need to support the weight of the product evenly and withstand high - temperature firing. The composite corundum - mullite trays have high strength and thermal stability, which can meet the requirements of sanitary ware firing, reducing the risk of product deformation.
Roof tiles are often fired in large quantities. The trays need to be able to withstand repeated high - temperature cycles. Composite corundum - mullite trays have a long service life under such working conditions, which can improve the production efficiency of roof tiles and reduce production costs.
In the temperature range of 1000°C - 1400°C, the deformation risk of trays can be assessed through some scientific methods. For example, we can measure the deformation rate of the tray under different temperature conditions and establish a deformation risk model. Based on this model, we can develop a corresponding life management strategy.
Life management of trays mainly includes two aspects: aging identification and replacement cycle determination. Here are some practical aging identification techniques:
As for the replacement cycle, it depends on the specific application scenario and usage frequency. Generally speaking, for trays used in high - precision applications such as mosaics, the replacement cycle may be shorter, about 3 - 6 months. For trays used in less demanding applications such as roof tiles, the replacement cycle can be extended to 6 - 12 months.
Many ceramic manufacturers have faced the problem of product quality decline due to tray issues. For example, a mosaic manufacturer used to have a high rate of mosaic collapse during firing. After switching to composite corundum - mullite trays, the collapse rate decreased by more than 80%, and the kiln yield increased significantly.
"Since we started using composite corundum - mullite trays, our production efficiency has increased by 30%, and the product quality has also been greatly improved. We no longer have to worry about the problem of product deformation during firing." - A ceramic factory manager
In conclusion, choosing the right tray material and managing its service life scientifically are crucial for improving ceramic firing quality and production efficiency. If you want to learn more about ceramic tray selection and management, click here to download the "Ceramic Tray Selection White Paper" PDF or join our ceramic kiln technology exchange group.
