1. Sponge processing process
The first is the selection of sponge, because each sponge body may have different mesh even if the same batch of sponges, the mesh standard must be carefully checked before processing; the second is that the cutting size of sponge should be accurate; and finally, the processed sponge products should be guaranteed to have no inclination.
2. Size mixing process
The formula selection must ensure the best condition of the consistency and fluidity of the slurry, so as to ensure that the ceramic foam filters for casting in the sizing process can be evenly sized and reach the required sizing weight.
3. Sponge modification process
Sponge modification is to prepare for the sizing process, improving the hanging performance of sponge and making a sizing uniform.
4. Dip sizing process
The modified dry sponge products are evenly coated into green bodies by the adjusted slurry on the roller press. For the sponge products with different mesh sizes, different consistency slurry is needed. Otherwise, the sizing effect can not be achieved.
5. Drying process
The drying process is mainly to let the sizing semi-finished product volatilize the moisture, which is generally controlled below 1.0%. For products with larger specifications, it is necessary to control the drying environment, such as temperature and humidity, to prevent drying deformation and crack defects.
6. Firing process
The firing process is the last process in production, and the firing temperature is generally 1350 ~ 1450℃.
7. Quality inspection process
Because of their porous structure, foam ceramics are more or fewer dropout products. The filter itself is used to filter inclusions, but its own slag will play the opposite role, leading to casting scrap. Therefore, in the quality inspection process, in addition to testing the appearance and internal quality of qualified, cleaning slag is also very necessary.