Production Process of Ceramic Fiber Shaped Products
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Author : SUNTHERM
Update time : 2025-09-03 17:10:12
1. Raw Material Preparation and Formulation
（1）Ceramic fiber shaped products are manufactured using high-purity ceramic fiber cotton as the core raw material. According to the specific application requirements (such as temperature resistance, anti-erosion properties, or mechanical strength), different components are added:
（1）Ceramic fiber shaped products are manufactured using high-purity ceramic fiber cotton as the core raw material. According to the specific application requirements (such as temperature resistance, anti-erosion properties, or mechanical strength), different components are added:
l Zirconia-containing shaped products: addition of zirconia improves high-temperature stability.
l High-alumina shaped products: increased alumina content enhances structural strength and thermal shock resistance.
Binders (organic or inorganic resins), dispersants, and other additives are also incorporated to improve fiber dispersion and molding performance.
2. Vacuum Forming Process
（1）Slurry Preparation:
Ceramic fiber cotton is mixed with water, followed by the addition of dispersants. The mixture is stirred at high speed to ensure uniform fiber dispersion. Auxiliary fibers (e.g., zirconium boride fibers, silver fibers) and binders are then added, creating a homogeneous slurry. Slurry concentration, stirring speed, and fiber length are strictly controlled to guarantee consistent product quality.
Ceramic fiber cotton is mixed with water, followed by the addition of dispersants. The mixture is stirred at high speed to ensure uniform fiber dispersion. Auxiliary fibers (e.g., zirconium boride fibers, silver fibers) and binders are then added, creating a homogeneous slurry. Slurry concentration, stirring speed, and fiber length are strictly controlled to guarantee consistent product quality.
（2）Vacuum Filtration Forming:
The slurry is poured into custom-designed molds, where excess water is removed using vacuum filtration. This step enables directional fiber deposition and preliminary consolidation. Molds are designed according to customer drawings to accurately reproduce complex shapes such as tubes, arcs, cones, or domes.
The slurry is poured into custom-designed molds, where excess water is removed using vacuum filtration. This step enables directional fiber deposition and preliminary consolidation. Molds are designed according to customer drawings to accurately reproduce complex shapes such as tubes, arcs, cones, or domes.
（3）Drying:
The wet body is dried at approximately 150 °C for 15–20 hours to remove residual moisture and prevent cracking or deformation during subsequent sintering.
The wet body is dried at approximately 150 °C for 15–20 hours to remove residual moisture and prevent cracking or deformation during subsequent sintering.
3. High-Temperature Sintering and Performance Enhancement
（1）Sintering:
The dried bodies are fired in a high-temperature furnace at around 1600 °C for 30 minutes. This strengthens the bonding between fibers, resulting in products with low shrinkage, high strength, excellent insulation, and good impact resistance.
The dried bodies are fired in a high-temperature furnace at around 1600 °C for 30 minutes. This strengthens the bonding between fibers, resulting in products with low shrinkage, high strength, excellent insulation, and good impact resistance.
（2）Surface Treatment:
Depending on the application, the sintered products may undergo surface coating with hardeners or refractory mortar to improve resistance to corrosion and erosion. For instance, peep sight blocks used in petrochemical furnaces are often coated with refractory mortar to withstand hot gas flow.
Depending on the application, the sintered products may undergo surface coating with hardeners or refractory mortar to improve resistance to corrosion and erosion. For instance, peep sight blocks used in petrochemical furnaces are often coated with refractory mortar to withstand hot gas flow.
4. Quality Inspection and Customized Production
Inspection:
（1）Finished products undergo rigorous testing for dimensional accuracy, compressive strength, thermal conductivity, and permanent linear change on heating, ensuring compliance with industry standards (e.g., permanent linear change ≤ –3%).
（1）Finished products undergo rigorous testing for dimensional accuracy, compressive strength, thermal conductivity, and permanent linear change on heating, ensuring compliance with industry standards (e.g., permanent linear change ≤ –3%).
（2）Customization and Stock Supply:
Customized production is available according to customer drawings, offering a one-stop service from design to finished products. Meanwhile, certain standard parts (such as casting caps used in non-ferrous metallurgy) are kept in stock to shorten delivery lead times.
Customized production is available according to customer drawings, offering a one-stop service from design to finished products. Meanwhile, certain standard parts (such as casting caps used in non-ferrous metallurgy) are kept in stock to shorten delivery lead times.
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