Selecting the right material for ceramic kiln trays is crucial for optimizing the ceramic firing process. This article delves into a detailed comparison between composite corundum - mullite and traditional refractory bricks, aiming to provide technical decision - making support for industry professionals.
In the realm of ceramic kiln tray materials, the performance differences between composite corundum - mullite and refractory bricks are significant. We will analyze these differences from four key aspects: thermal stability, thermal shock resistance, wear resistance, and chemical inertness.
| Performance Aspect | Composite Corundum - Mullite | Refractory Bricks |
|---|---|---|
| Thermal Stability | High, with minimal deformation in the 1000°C - 1400°C range | Relatively lower, higher risk of deformation at high temperatures |
| Thermal Shock Resistance | Excellent, can withstand rapid temperature changes | Moderate, more prone to cracking under thermal shock |
| Wear Resistance | Good, long - lasting in abrasive environments | Average, may wear out faster |
| Chemical Inertness | High, less likely to react with ceramic materials | Varies, may have chemical reactions in some cases |
Different ceramic products have specific requirements for kiln tray materials. Let's explore some common application scenarios.
Mosaic tiles are small in size and require high - precision firing. Composite corundum - mullite trays, with their excellent thermal stability and wear resistance, can ensure consistent firing quality and reduce the risk of product defects. Refractory bricks may not be as suitable due to their relatively lower thermal stability, which can lead to uneven firing and deformation of mosaic tiles.
Sanitary ware products are large and have complex shapes. The high thermal shock resistance of composite corundum - mullite trays is crucial in this application. During the firing process, the trays need to withstand rapid temperature changes without cracking. Refractory bricks may crack under such conditions, affecting the firing quality of sanitary ware.
Roof tiles are often fired in large quantities and are subject to abrasive forces during handling. Composite corundum - mullite trays, with their good wear resistance, can maintain their integrity over multiple firing cycles. Refractory bricks may wear out more quickly, increasing the cost of tray replacement.
In the temperature range of 1000°C - 1400°C, both composite corundum - mullite and refractory bricks have different aging trends. As the temperature increases, the risk of deformation for both materials rises. For composite corundum - mullite trays, regular inspections should be carried out at high temperatures to detect any signs of deformation early. For refractory bricks, the frequency of replacement may need to be increased to ensure firing quality.
Here is a simple temperature - related aging trend table:
| Temperature Range | Composite Corundum - Mullite | Refractory Bricks |
|---|---|---|
| 1000°C - 1200°C | Low deformation risk, normal wear | Moderate deformation risk, increased wear |
| 1200°C - 1400°C | Increased deformation risk, accelerated wear | High deformation risk, severe wear |
One common problem in the ceramic industry is tray warping during continuous firing. This can be caused by uneven heating, thermal stress, or material fatigue. For composite corundum - mullite trays, ensuring uniform heating and proper cooling can reduce the risk of warping. For refractory bricks, using better - quality materials and improving the firing process can also help alleviate this issue.
"We switched to composite corundum - mullite trays for our mosaic tile production, and the firing defect rate has decreased by 30%. The trays are more durable and have significantly improved our production efficiency." - A ceramic factory technical director
Have you ever encountered product scrap due to tray deformation? If you are a technical leader in the ceramic industry, this article provides practical technical judgment and usage suggestions to help you make scientific material selections, improve firing yields, and enhance equipment utilization.
Get more in - depth information and detailed technical guidance by downloading the 'Ceramic Tray Selection White Paper' PDF.
