Project country: Russia
Date: 2022.08
Application: Refractory brick mold
Project detail: The brazed liners used as wear resistant parts for the refractory brick mold, reducing abrasion, improving working efficiency
Material used: Tungsten carbide tiles vacuum brazed on steel backing plates
In the demanding field of refractory brick manufacturing, mold durability and precision are paramount. Refractory mixes, composed of hard, abrasive particles like alumina and magnesia, rapidly degrade conventional tool steel molds, leading to frequent downtime, inconsistent brick quality, and high replacement costs.
The solution lies in Tungsten Carbide (WC) liners. Tungsten carbide, used in its cemented carbide form with a cobalt binder, offers an unparalleled combination of extreme hardness (up to 2000 HV) and high compressive strength. This enables WC liners to withstand the severe abrasion and high pressures of hydraulic or mechanical pressing orders of magnitude longer than steel.
As precision inserts or full-length sleeves within the mold body, these liners maintain exact dimensional tolerances and superior surface finish over hundreds of thousands of pressing cycles. This directly translates to consistent brick quality, reduced scrap, and significantly less machine downtime for mold changes. While the initial investment for a WC-lined mold is higher, the Total Cost of Ownership is drastically lower due to its extended service life and sustained productivity.
Key applications include liners for mold boxes, pressing shoes, and plunger tips in the production of high-alumina, magnesia-carbon, and other abrasive brick types. The ongoing evolution of WC grades, including finer grain structures and specialized binders for corrosive environments, continues to push the boundaries of performance.
Ultimately, Tungsten Carbide liners are not just a wear component; they are a transformative technology that ensures precision, efficiency, and economic viability in modern refractory brick production.
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