1. Raw Material Preparation & Formulation
Ceramic fiber special-shaped parts are manufactured using premium ceramic fiber wool as the core material. Formulations are adjusted according to performance requirements such as high-temperature resistance and wind erosion resistance. For example, zirconia-containing shapes include zirconium oxide to enhance extreme heat performance, while high-alumina grades incorporate more alumina for improved structural stability. Additional binders (such as resin) and additives (such as dispersants) are used to improve fiber dispersion and forming quality.
2. Precision Vacuum Forming Process
Slurry Preparation: Fiber wool is mixed with water in precise ratios, then dispersants like hydroxypropyl methylcellulose are added for uniform dispersion. Auxiliary fibers (e.g., silver fiber, zirconium boride fiber) and binders are incorporated to create a homogenous slurry. Key parameters such as slurry concentration, mixing speed, and fiber length are strictly controlled to prevent fiber entanglement.
Vacuum Suction Molding: The slurry is poured into custom-designed molds (pipe, cone, dome, and other complex shapes) based on client drawings. Vacuum filtration removes excess water, allowing fibers to align and form a stable wet shape.
Drying: The wet body is dried at 150°C for 15–20 hours to remove residual moisture and prevent cracking during sintering.
3. High-Temperature Sintering & Performance Enhancement
Sintering: The dried shapes are fired in a high-temperature kiln at 1600°C for 30 minutes. This strengthens the fiber bonds, creating a durable ceramic structure with low shrinkage, high insulation, and impact resistance.
Surface Treatment: Depending on the application, surfaces may be coated with hardening agents or refractory mortar to improve corrosion resistance and erosion resistance-for example, petrochemical observation ports require refractory mortar to withstand hot gas flow.
4. Quality Control & Custom Manufacturing
Testing: Finished products undergo rigorous testing for dimensional accuracy, compressive strength, and thermal conductivity to ensure compliance with industry standards (e.g., permanent linear change ≤ -3%).
Custom Solutions: We offer full custom manufacturing services based on client drawings, from design to final product. Standard parts such as casting caps for non-ferrous metals are also available from stock for faster delivery.
With advanced production technology, strict quality control, and tailored solutions, our ceramic fiber special-shaped parts deliver exceptional performance in metallurgy, petrochemical, power generation, and high-temperature industrial applications worldwide.
