AZS refractory bricks are scientifically called fused zirconium corundum bricks. They are made by completely melting the raw materials and casting them in a mold to cool and solidify. They are mainly used in glass kilns. During production, the casting method varies according to the usage scenario and the specific location in the kiln.
What are the casting methods of AZS bricks?
The production process of AZS bricks mainly includes several stages, including raw material formulation, high-temperature smelting, casting, and cooling. Among them, casting is the key step to determine the shape and internal structure of the brick body.
According to different casting methods, AZS bricks can be divided into: ordinary casting, tilting casting, quasi-shrinkage-free casting, and shrinkage-free casting; Different casting processes have different casting methods. At present, the most commonly used method for ordinary casting is electric melting. AZS products can meet the use requirements of various parts of ceramic melting furnaces, soda ash kilns, and glass kilns. They are resistant to erosion and corrosion and have a long service life.
Type 1. Ordinary casting (PT)
This is the most common casting method, in which the molten AZS liquid is poured directly into the mold.
Location of shrinkage cavities: Shrinkage cavities are usually located in the lower part of the gate.
Application: This method is suitable for the upper structure of the molten pool and the area of moderate erosion.
Type 2. Tilt casting (QX)
By tilting the mold, shrinkage cavities are moved to the lower end of the brick. In tilt casting, shrinkage cavities are concentrated at one end, while the other end is still very dense. The tilt angle is usually between 30° and 35°.
Purpose: This method is mainly used for molten pool wall bricks, which can effectively reduce the impact of shrinkage cavities on the strength of the pool wall.
Type 3. Quasi-shrinkage-free casting (ZWS)
This method uses vertical casting, and the casting size is larger than the required size. After annealing, most of the upper part containing shrinkage cavities is removed.
Purpose: This method is suitable for molten pool wall bricks and other areas requiring higher density.
Type 4. Shrinkage-free casting (WS)
This method uses vertical casting, and the casting size is larger than the required size. After annealing, the upper part containing shrinkage cavities is removed, resulting in a very dense structure. Pore-free casting has a higher cost, but better performance.
Purpose: This method is suitable for areas with severe erosion such as liquid holes, kiln racks, molten pool corners, and road surfaces.
Effects of different casting methods on the properties of composite AZS bricks
· Location of shrinkage holes: The location of shrinkage holes affects the strength and thermal shock resistance of bricks.
· Density: Different casting methods affect the density of refractory bricks, which in turn affects their wear resistance and corrosion resistance.
· Porosity: The porosity of bricks affects its thermal conductivity and thermal shock resistance.
Choice of casting method
Choosing a suitable casting method requires comprehensive consideration of the following factors:
· Application location: Different locations have different requirements for bricks, such as the top of the melting tank, the tank wall and the liquid hole.
· Working conditions: Conditions such as temperature, atmosphere, corrosiveness, etc. will also affect the choice of bricks.
· Performance requirements: Consider performance requirements, including strength, density and thermal shock resistance.
How to choose a suitable casting method for AZS bricks?
· Select according to the application location;
· Select according to the operating conditions: Consider factors such as temperature, atmosphere and corrosiveness;
· Select according to performance requirements;
· Consider economic factors: Consider the overall cost-effectiveness.
Selection of casting method The selection of AZS kiln bricks is a systematic project. It requires comprehensive consideration of multiple factors and scientific and reasonable selection to effectively improve the service life and production efficiency of the kiln. Hongtai Refractory Factory can provide you with comprehensive solutions and guidance. If you have any needs, please feel free to contact us.
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