Production process of ceramic fiber blankets

Ceramic fiber blankets are thermal insulation materials suitable for high-temperature environments. Their production involves a precise combination of raw materials, processes, and technologies. Below is the production process for réfractaire ceramic fiber blankets.

Ceramic fiber raw material selection and pretreatment

The main raw materials for ceramic fiber blankets include high-purity alumina and silica powder, mixed in a certain proportion. The purity of the raw materials directly affects the temperature resistance and chemical stability of the fibers. Par exemple, a well-known ceramic fiber manufacturer uses alumina with a purity of over 99% to ensure that the product maintains stable performance even at a high temperature of 1400℃.

Melting and fiber formation

The mixed raw materials are melted in an electric arc furnace or resistance furnace at temperatures exceeding 2000℃. The molten liquid material is then spun into fibers using a high-speed airflow or centrifugal spinning process. One company has adopted an improved spinning technology that results in more uniform fiber diameter, enhancing the flexibility and tensile strength of the blanket.

Fiber molding and needle reinforcement of ceramic fiber blankets

The fibers are evenly distributed in the settling chamber to form a rough fabric. It then enters a needle punching machine, where thousands of needles pierce through the fibers, causing them to interweave and enhancing the structural strength of the blanket. One factory significantly improved the tear resistance of its products by optimizing the needle punching density (e.g., 80-100 needles per square centimeter).

Heat treatment and post-processing

After molding, the fiber blankets need to undergo high-temperature heat treatment to remove organic binders and improve crystallinity. Par exemple, a certain brand of ceramic fiber blankets is heat-treated at 1200℃ for 2 hours to achieve a long-term service temperature of 1260℃. Enfin, after cutting, rolling, and other processes, they are made into finished products of different specifications.