In the ceramics manufacturing industry, controlling deformation during the firing process is a persistent challenge that can significantly impact product quality and production efficiency. This guide delves into practical strategies for controlling ceramic deformation, with a focus on the layout of tray grooves and thickness gradient design.
High - temperature firing of ceramic products often leads to common defects such as warping and cracking due to uneven heating of the trays. When the tray is exposed to uneven heat, different parts of the ceramic on the tray expand or contract at different rates. For example, in a large - scale ceramic manufacturing plant, the warping rate of ceramic products could reach up to 15% and the cracking rate about 8% before implementing proper deformation control measures.
Composite corundum - mullite trays offer a promising solution. By optimizing the geometric structure, we can improve heat conduction uniformity and reduce deformation. The groove distribution pattern on the tray is crucial. A well - designed groove can guide the flow of heat, ensuring that heat is evenly distributed across the tray surface. For instance, a tray with a regular groove pattern can reduce the temperature difference across the tray by up to 20°C compared to a tray without grooves.
The thickness gradient design of the tray also plays an important role. A tray with a proper thickness gradient can adjust the heat absorption and dissipation rate in different areas. This design principle helps to balance the heat field, reducing the stress caused by uneven temperature and thus minimizing warping and cracking.
The installation method of the tray, including stacking spacing and positioning hole layout, has a synergistic effect with the heat conduction characteristics of the kiln car. The stacking spacing affects the air circulation between trays, which in turn influences heat transfer. If the stacking spacing is too small, heat may accumulate, leading to over - heating in some areas. An appropriate stacking spacing, usually around 3 - 5 cm, can ensure good air circulation and uniform heat distribution.
The positioning hole layout helps to fix the tray accurately on the kiln car, ensuring stable heat transfer between the tray and the kiln car. A well - designed positioning hole can improve the heat transfer efficiency by about 15%.
Let's look at some real - world examples. In a ceramic factory, after implementing the improved tray design and installation method, the deformation rate of ceramic products decreased from 23% to 8%, and the yield rate increased from 70% to 90%. These data clearly demonstrate the effectiveness of the proposed strategies.
| Before Improvement | After Improvement |
|---|---|
| Deformation rate: 23% | Deformation rate: 8% |
| Yield rate: 70% | Yield rate: 90% |
For on - site technicians, practical detection methods and improvement plans are essential. Infrared thermometers can be used to measure the temperature distribution on the tray surface, helping to identify areas with abnormal temperatures. Deformation measurement tools can accurately measure the degree of warping and cracking of ceramic products. By using these tools, technicians can quickly adjust the process parameters, such as the firing temperature and time, to improve the product quality.
In conclusion, by mastering the layout of tray grooves and thickness gradient design, ceramic manufacturers can significantly improve the yield rate of ceramic products. Our composite corundum - mullite trays, made of high - quality materials, offer excellent dimensional stability at high temperatures, effectively reducing the risk of ceramic product deformation. If you want to enhance your ceramic production efficiency and product quality, click here to learn more about our innovative ceramic trays.
