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Process Engineering

Hydraulic Pressing
Alfred Kaiser
LAEIS GmbH
kaiser@laeis-
gmbh.com

of Advanced Ceramics
Abstract • possibility of „dry“ pressing Advanced Hydraulics and
• low binder content
Uniaxial hydraulic pressing is the Electric Control Systems
• high throughput capacities
most common shaping technology • moderate investment costs. Naturally one of the most important
for ceramic products. However, On the other hand, there have been elements of hydraulic presses is the
when production technologies for also some limitation factors for uni- hydraulic system. High pressing
new advanced ceramic products axial hydraulic pressing of advanced forces have to be combined with fast
with high quality requirements are ceramics reported in the past, action, but also with high precision.
discussed, in most cases this tech- namely: Energy consumption has to be kept
nology is considered to be only sec- • only simple geometries possible at a minimum, service and mainte-
ond choice. Other technologies like • limited dimensions of the speci- nance intervals extended to a maxi-
isostatic pressing, injection mould- mens to be pressed mum. Increasing importance is also
ing, pressure casting, tape casting • comparably high variations in the given to reduction of environmental
etc. seem to provide better quality green density; especially from top or working place impact, especially
products, even if they are more to bottom (3...10 % variation are the reduction of the noise level.
expensive, have much lower pro- reported) The new generation of hydraulic sys-
duction capacities or are limited in • limited dimensional accuracy, e.g. tems for the HPF presses offers the
other factors. thickness variations in the range of following features (among others):
The paper describes new possibilities ± 10 %. • scalable hydraulic units having the
for shaping of advanced ceramic When it comes to set up a produc- same design pattern
products with a wide variety of tion technology for high quality • regulated axial piston pumps for
dimensions and aspect ratios and technical ceramic products, thus an effective energy utilization
high quality requirements. Recent very often uniaxial hydraulic press- • proportional valves for an opti-
developments in pressing technolo- ing is not at all discussed as a real mum regulation of all cylinders
gies are shown and results of press- alternative for shaping in competi- • separate filtering and cooling cir-
ing tests for advanced ceramics are tion to isostatic pressing (cold and cuit for a constant good oil quality
presented which demonstrate that hot), injection moulding, slip cast- and cleanliness
highest quality can be achieved ing, pressure casting, extrusion, • valve blocks in special design,
using uniaxial hydraulic presses. injection moulding, tape casting etc. arranged close to the energy con-
Finally, a selection of application [5 - 10]. sumers; resulting in short reaction
examples is given, indicating However, in the last decade many times
advanced ceramic products already advances have been made in • auxiliary cylinders, moving the
hydraulically pressed in industrial hydraulic pressing technology which press plunger quickly and precise-
scale. allow to overcome the above men- ly thus reducing dead times
tioned limitations and open up com- • sealed and pressurized hydraulic
pletely new fields for advanced system for utmost oil cleanliness
ceramics production [11 - 14]. In the and improved service life
Introduction • encapsulated power unit with
following some aspects of improve-
Hydraulic pressing is a well known ments made in hydraulic pressing noise insulation, reducing the
and widespread technology for technology are reported, some char- noise level to < 80 dBA (Fig. 1)
shaping of ceramics [1 - 4]. Especial- acteristic data of samples obtained • flexible positioning of the power
ly for the production of "classic" using this advanced technology are unit, possible on both sides of the
ceramics like silicate ceramics (floor press and at different height levels. Fig. 1
given and examples of new applica- Hydraulic power
and wall tiles, facing elements etc.), tions resulting thereof are shown. Besides the performance of the unit in modular
for all types of refractories (even if hydraulic system and the precision design
many of them nowadays have to be
regarded as "advanced ceramics") Recent Improvements in
and for many types of kiln furniture Hydraulic Pressing
the uniaxial hydraulic pressing ist the
mostly used shaping technology. Technology
Also technical ceramic products (in Quality requirements are increasing
this paper "technical ceramic" will be constantly for practically all types of
referred to as ceramic produced shaped ceramic products. Thus it
mainly from synthetic powders, has become necessary to improve
either oxide or non-oxide) are made also the performance of presses per-
already using hydraulic pressing. But manently. Laeis GmbH, being one of
up to now this has been limited to the leading supplier of high duty
smaller sizes with additional restric- hydraulic presses especially for
tions regarding the complexity of refractories, but also for many other
the specimen and their aspect ratio. industries, made numerous contri-
Main advantages of uniaxial butions to define a new level of
hydraulic pressing technology are: state-of-the-art pressing technology.

cfi/Ber. DKG 84 (2007) No. 6 E 27


Process Engineering
• simple operation, no need for stand. The design of the windows is
manual setting of slow speed and highly graphic oriented with very lit-
deceleration distance tle wording and standardized sym-
• very accurate repetitive move- bols. New pressing programs are
ment, maintaining an optimum established quickly using the inte-
product quality over the complete grated copy function, the storage
production time capacity is limited only by the capac-
• reduction of cycle time. ity of the hard drive.
Internal connections are realized The pressing regime controls the
with Profibus as a worldwide stan- end of the pressing stroke either by
dardized system. The bus system reaching a predefined "nominal"
allows to replace extensive parallel product thickness or by reaching a
cabling by one single bus cable and nominal final pressure or by a com-
reduces the switch cabinet size by bination of both (whatever comes
about 30 %. Comprehensive diag- first). Always superimposed is a "tol-
nosis options of the bus system allow erance window" for accepted upper
for short commissioning times and and lower limits for pressure and
Fig.2 Graphic display; control panel
improved plant availability. In case of thickness (Fig. 3). Depending on the
service needs, complete bus mod- defined pressing regime the press
ules can be replaced without discon- control tries to compensate for
necting a single line or screw. changes in the material bulk density
Hardware and software, both in or compactibility, e.g by modifying
modular design, provide for a totally the pressure or adjusting the filling
integrated automation with intrinsic height, as long as this is possible
communication features. Connec- within the given tolerances.
tions to process host control systems In order to achieve an optimum
can be provided easily as well as pro- product quality, the setup allows to
duction data storage for quality con- adjust many parameters in a wide
trol and documentation. range, e.g.:
Even very special features like an • mould filling box movement
e-mail function from the press to a • punch entry speed
preselected address or to a mobile • speed ratio upper punch / mould
phone are possible. The control sys- frame
Fig. 3 Pressing regime of the mechanical parts also the con- tem can be scaled depending on the • pressure increase curve
trol system to a great extend con- requirements of the individual • pressure holding time
tributes to the overall quality of a process, according to customers • de-aeration strokes
hydraulic press. Laeis press control request. • ejection speed
systems are based on Simatic S7 PLC A specially developed, window • and many others.
and an industrial panel PC with stan- based application software ("ProVi-
dard basic software (e.g. WIN 2000). Control") allows a product oriented Vacuum Technology
Siemens EB32 Motion controllers are entry of data. Thus, setting of pro-
Pressing of powders or granulated
used for closed loop control of all duction parameters is possible with-
material in dry, semi-wet or wet con-
axes. Main advantages of closed out knowledge of the internal
dition often results in microstructure
loop control are: machine functions, just by entry of
inhomogeneities, uneven density
• very precise approach of the point product specific parameters. An
distribution and/or formation of lay-
of destination, independent of intelligent control minimizes the
ers, even when de-aeration strokes
load, oil viscosity and press mater- number of input parameters. Thanks
are applied. These effects are mainly
ial compactibility to windows technology (Fig. 2) the
caused by entrapped air, due to
operator interface has a clear process
insufficient release of the air before
oriented structure, easy to under-
and during compaction.
A well proven solution for this prob-
Fig. 4
Density distribution lem is the vacuum pressing technol-
(vacuum) ogy, where the air inside the materi-
al is removed to a certain (selectable)
level before the compaction starts.
With this technology, additional de-
airing cycles and slow pressing
speeds can be reduced. A recently
designed, new economic vacuum
pressing system reduces the volume
to be evacuated to a minimum, thus
enabling a very short evacuation
time of about 2...4 s and reducing
the energy consumption of the vac-
uum pump. A pre-evacuation con-
tainer additionally shortens the
pressing cycle. The evacuation can
take place via upper and lower die or

E 28 cfi/Ber. DKG 84 (2007) No. 6


Process Engineering
via upper die only, depending on ity of the material distribution in the
material characteristics and product mould, an adequate material prepa-
dimensions. ration process must be ensured. This
Resulting advantages of vacuum process has to provide for minimal
pressing technology are the avoid- variations of the bulk density of the
ance of lamination, a higher green body (both within one mould filling
density and an even density distribu- or from filling to filling) and for a
tion of the product (Fig. 4) as well as good (and constant) flowing behav-
an improved productivity thanks to ior.
equipped with vacuum technology Fig. 5 Al2O3 sample
the reduced cycle time. Several This pre-requirement being fulfilled, pressed without
(Fig. 6). As material for these tests a
materials and product dimensions the mould filling step itself has to be and with vacuum
reactive alumina powder CT3000
can be realized only with vacuum adapted according to the individual
with 99,7 % Al2O3 (Almatis,D) was
technology, whereas conventional requirements of each process.
used, which was spray dried at the
pressing technology, even with mul- Therefore, various modifications of
LAEIS test center Alpha Ceramics in
tiple de-aeration strokes, leads to the mould filling systems have been
Aachen. The binder system with the
destruction of the pressed body after developed. Basically, it can be distin-
main components acrylate and wax
release of the pressure (Fig. 5). In guished between volumetric and
had been developed for other appli-
special cases it can be advantageous gravimetric filling systems. Gravi-
cations and was not optimized for
to combine vacuum technology metric systems normally have a high
this special task. The binder content
with backstrokes of the die (which in weighing accuracy and result in
was in the range of 2 mass %. The
this case are no longer de-aeration small variations of the weight of the
powder was dry pressed to round
strokes). pressed specimen, but are difficult
discs in a single cavity steel mould,
Vacuum pressing technology is espe- for automation. Volumetric filling
diameter 193 mm. No specific mea-
cially recommended for: systems on the other hand can easi-
sures were taken with respect to sur-
• granulates with a high densifica- ly be automated, but the weight
face treatment (polishing etc.) of the
tion factor (i.e. mixtures having a accuracy depends on material char-
dies. Discs with various thicknesses
low bulk density before pressing acteristics. For most of the applica-
were pressed under various pres-
and/or reaching a high green den- tions the accuracy of volumetric fill-
sures, using the same mould with
sity (low residual porosity) after ing systems is sufficient, but some-
various filling heights (Fig. 7).
pressing times gravimetric systems or even
The mould was filled volumetrically.
• extremly fine granulates, e.g. very special filling systems have to be
Densification took place after evacu-
fine spray dried material for tech- used. Such special systems can be
ation of the mould to a residual
nical ceramics external filling templates, which are
atmospheric pressure of < 50 mbar.
• not granulated highly dispersed filled gravimetrically or volumetrical-
After pressing, the disc was ejected
powders which for conventional ly and are then transferred to the
pressing technology would have to mould (e.g. vacuum assisted). Other
be granulated possibilities are filling systems with Fig. 6
• product geometries with large vol- double layer options. It has to be ALPHA 800 press
ume or with high aspect ratios mentioned, that the higher the
(thin plates, rods etc.), where the required accuracy and complexity of
air needs to move a long distance the filling system, the more the nec-
to the gap between die and mold essary cycle time will be extended.
frame The further downstream production
• mixtures with higher plasticity, steps, especially the drying and fir-
which are pressed with higher con- ing process, will of course also con-
tent of water or other liquid tribute to the quality of the final
binders. product. However, this is valid for all
It has to be mentioned, that the different types of shaping and there-
application of vacuum technology fore these process steps are not
requires special care in design and looked at here. The following Fig. 7
Pressed alumina
fabrication of the moulds to be used. description of sample properties will plates of various
concentrate on properties of green thicknesses
Moulds and samples.
Mould Filling Systems
When the quality of pressed ceramic Properties of Technical
products is discussed, especially with Ceramic Samples
respect to thickness variation or den- Obtained by Uniaxial
sity distribution, it is essential to con-
sider also the mould filling process. Hydraulic Pressing
The best pressing technology can Technology
not overcome major inhomo-
geneities in the material distribution Experimental Procedure
after mould filling (except when the In order to demonstrate the possibil-
press body has a sufficient plastic ities of state-of-the-art hydraulic
behavior, which is not the case for pressing technology, a series of
most technical ceramic products). In specimen have been pressed on a
order to achieve a good homogene- LAEIS press type ALPHA 800

cfi/Ber. DKG 84 (2007) No. 6 E 29


Process Engineering
automatically and removed from the
mould manually.

Green Strength
The plates could be removed from
the mould after pressing without any
problems. Even thin plates with 1
mm thickness could be handled
without destruction (Fig. 8), even
though the binder system was not
optimized. If no vacuum was

Tab. 1 Linear
springback effect
depending on fill- Tab. 2 Thickness and density variation of green alumina plates
ing height and
applied pressure applied, however, the plates were and accordant average thickness,
destroyed immediately after releas- but also the standard deviation
ing the pressure (Fig. 9). decreases with increasing pressure.
The green density values are also
shown in Tab. 2, calculated from the
Dimensional Accuracy, Densi- weight and dimensions of each indi-
viual plate and given as average val-
ty and Density Distribution ue with the corresponding standard
After pressing and ejection from the deviation for each test pressing
mould cavity, the plates underwent a series. The absolute density values
springback in diameter (re-expan- should not be discussed here,
sion of the material), depending on because the aim of these tests was
the plate thickness and on the not to obtain maximum density, but
applied pressure (Tab. 1). A spring- to demonstrate reliability and repro-
back in vertical direction was pre- ducibility of the hydraulic pressing
vented by ejection under load. The process. Again, the 3 test series with
green plates showed a very high 16 mm filling height can be com-
dimensional accuracy. Variations in pared to each other, showing a
green plate thicknesses are shown in steady increase in density with
Tab. 2. increasing pressure. More important,
The average values and standard however, is the reproducibility of the
deviations given for each set of filling green density within each test series,
height and densification pressure having standard deviations of typi-
represent a collective of 4-10 plates cally < 0,4 %.
pressed under the same conditions In an earlier test series, also thickness
and 4 thickness measurements of and density variations were investi-
each plate at different spots. Though gated on similar samples after firing.
the thickness variations are already The results are shown in Tab 3. In this
quite low, they can be reduced fur- table, only one plate of each type
ther in an optimized automatic was investigated. Each line of the
Fig. 8 process, because the data given in table represents values of one plate,
Manual handling of thin plates immediately after pressing Tab. 2 are obtained with manual fill- where the thickness and density
ing of the mould with small quanti- were measured at up to 30 spots
ties of powder and without a special each, distributed over the whole area
adjustment of the pressing die paral- of the plate. Again the results are
lelism. Both factors contribute to very good, with fluctuations only in
deviations in thickness, the first one the range of typically < 2 % (it has to
mainly between the plates, the sec- be noted that the values in Tab. 3 are
ond one within a single plate. Natu- absolute values, not standard devia-
rally, the percentage of deviation is tion values!). Naturally, the thinnest
increasing with decreasing thickness. plate with a fired thickness of < 1 mm
The densification factors, also given again has a bigger percentage of
in Tab. 2, can not be discussed in thickness fluctuation, but the
detail, because the different test absolute value is in the same range as
pressings were performed with dif- the other plates.
ferent pressing parameter combina-
tions. However, the data of the 3
series with 16 mm filling height (with Surface Quality
specific pressures of 5, 10 and 15 The plates show a very smooth sur-
kN/cm2) were obtained under con- face already in the green state. After
Fig. 9 stant conditions. They show a good firing a similar surface quality is
Destroyed plate (pressed without vacuum) consistency of densification factor obtained as with tape casted sheets,

E 30 cfi/Ber. DKG 84 (2007) No. 6


Process Engineering
without any machining of the Fig. 10
pressed products. A surface rough- Surface rough-
ness measure-
ness Ra of < 0,6 µm was measured at ment
one plate (Fig. 10).

Application Examples
A big variety of applications was
investigated in detail during the last
years and many of them have been
brought to industrial application.
The following section describes some
of these applications.

Sputtering Targets for


PVD Technology mina, alumina-zirconia, silicon car- the green strength of such plates is
bide, boron carbide and others are high enough to remove them from
For functional coating of TV screens,
used or are under investigation. the mould by means of a vacuum
displays, touchscreens etc. several
While vehicular protection armor gripper or even manually. This devel-
target materials are used which have
mainly show simple geometries (tiles opment opens up a possibility of
to be applied using the sputtering
of different size and thickness, rec- competing with tape casting tech-
technology (PVD = physical vapour
tangular or hexagonal), the body nology, but working at a much low-
deposition process). Since the sub-
protection armor generally are large er binder and solvent content and
strates are constantly increasing in
specimen with very complex shapes with a higher throughput capacity.
size, also the sources of the sputter-
(irregular curvatures in all dimen- This technology could be used also
ing material (so called "sputtering
sions). Despite these complex for production of fuel cell compo-
targets") have to become bigger and
shapes, industrial production must nents, e.g. for Ni based anodes of
bigger. In addition to the large
guarantee minimum thickness varia- anode-supported SOFC (solid oxide
dimensions, high dimensional accu-
tions over the whole area and even fuel cells) or for zirconia based mem-
racy and near net shaping are
density distribution at a high pro- branes of electrolyte-supported
required to reduce necessary
duction capacity. A special mould fill- SOFC. Uniaxial hydraulic pressing
machining and to avoid excessive
ing system has been developed to technology has also been successful-
loss of the sometimes very expensive
fulfil these requirements. Up to now, ly introduced for the production of
material (e.g. ITO = indium tin
three LAEIS vacuum presses are pro- bipolar plates for PEM (proton
oxide). Therefore, the moulds must
ducing body protection plates and exchange membrane) fuel cells,
be manufactured with very high pre-
several more have been supplied for based on resin bonded carbon mate-
cision. Vacuum pressing technology
the production of vehicle armor tiles. rial, which is pressed at elevated
is favorable for this process in order
to avoid lamination and to achieve temperatures where the resin shows
high green strength with low binder plastic deformation. Such bipolar
Substrates for Electronic plates have a highly structured sur-
content. The uniaxial hydraulic
pressing can be used as a precom-
and other Applications face (ducts for gas transport), e.g.
paction process for subsequent hot Most recent developments in dry with a depth of the structure patterns
isostatic pressing, offering the advan- powder pressing technology with of about 0,6 mm on both sides and
tage of getting much closer to the uniaxial hydraulic presses as well as an overall thickness of the plate of
required dimensions and to make development of improved binder about 1,8 mm (Fig. 11). For plates
better use of the capacity of the hot systems allow for pressing ceramic with dimensions of up to
isostaic press. In case an optimized plates with extremely high aspect 300 x 400 mm2 and a thickness of
separate firing process is used, this ratios, especially very thin plates of about 2 mm extremely low dimen-
process can completely dispense large sizes. It is possible e.g. to press sional toler ances (thickness varia-
with the cost-intensive hot isostatic thin sheets of 250 x 250 mm2 with a tions ± 20 µm) could be achieved.
pressing. Several presses are used in green thickness of < 1 mm (thickness
industrial production, producing ITO after firing down to the range of 0,5 Other Carbon Products
sputtering targets up to a size of mm). As ceramic materials various Another interesting example show-
1100 mm x 420 mm with a thickness alumina qualities, zirconia (Y-stabi- ing the ability to realize very complex
of only 8 to 10 mm. Other target lized) and silicon carbide have been shapes by uniaxial hydraulic pressing
materials like Al2O3, Al2O3-ZrO2 and investigated, but others are also pos- with sophisticated moulds are car-
ZnO-Al2O3 are under investigation. sible. With a suitable binding system bon filter elements for molten metal

Ballistic Protection Devices specific


fired plate thickness fired density
Tab. 3
Thickness and den-
pressure
Ballistic protection is a relatively new average max. min. range average max. min. range sity variation of fired
alumina plates
application for structural ceramics. kN/cm² mm mm mm mm % g/cm³ g/cm³ g/cm³ g/cm³ %

Monolithic armor plates and tiles are


10 0.90 1.02 0.86 0.16 17.7 3.85 3.907 3.804 0.103 2.7
used for personnel and vehicular pro- 10 3.06 3.09 3.02 0.07 2.3 3.85 3.873 3.806 0.067 1.7
10 4.12 4.15 4.09 0.06 1.5 3.83 3.853 3.779 0.074 1.9
tection. Their big advantage over 10 4.05 4.09 4.01 0.08 2.0 3.84 3.852 3.801 0.051 1.3
metal armor is their significantly low- 10 7.95 8.00 7.88 0.12 1.5 3.83 3.850 3.799 0.051 1.3
10 16.12 16.19 15.97 0.22 1.4 3.82 3.830 3.787 0.043 1.1
er weight. As ceramic materials alu-

cfi/Ber. DKG 84 (2007) No. 6 E 31


Process Engineering
Acknowledgements
The author wants to thank R. Kremer
(Alpha Ceramics GmbH, D) and K.
Müller (LAEIS GmbH, L), who did
most of the experimental and analyt-
ical work and made many valuable
contributions to the experimental
setup.

Fig. 11 PEM fuel cell bipolar plate Fig. 12 Carbon filter elements References
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electronic components like varistors processes. Precondition for premium
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Composites (2006), 495-506
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ments. Special systems based on vidual processes and an appropriate Rapid manufacturing of high-tech
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ISBN 90-5857-005-5, (2002), 259 ff
oped for the pressing of 2-compo-
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Uniaxial hydraulic pressing is a well Fertigungstechnologien; cfi/Ber.DKG
82 (2005), D21-2
known and proven technology in the [13] Lutz, R.: Double-layered refractory
ceramic industry. It was used for "tra- products automatically pressed from
ditional" ceramic products for many two different materials in one single
years. New developments make this working cycle; Interceram Refractories
technology available also for the pro- Manual (2006) 62–64
duction of a wide variety of advanced [14] Kremer, R.; Lutz, R.: Quality improve-
ment of shaped refractories by mod-
ceramics, offering many advantages
ern pressing technology; Preprints 49.
to the producer like high production Internat. Colloquium on Refractories
capacity and flexibility, near net Fig. 14 2-component sliding gate 2006, pp. 223–226

E 32 cfi/Ber. DKG 84 (2007) No. 6

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