What are the molding methods of monolithic refractories

In the refractory industry, monolithic refractories have become the core material for many industrial applications due to their excellent refractory performance, flexible construction methods and wide applicability. The molding methods of this type of material are diverse, and a variety of advanced molding technologies are used for different application scenarios and performance requirements.
Casting is one of the most commonly used molding methods for monolithic refractories. This process pours the pre-mixed refractory slurry into the mold, and demoulds it after solidification to obtain the refractory product of the desired shape. This method is particularly suitable for manufacturing refractory products with complex shapes and high dimensional accuracy requirements. During the pouring process, the preparation of the slurry is crucial. The slurry is required to have excellent fluidity and stability to ensure that the mold can be evenly filled during pouring. In addition, the curing time of the slurry and its environmental conditions need to be strictly controlled to ensure that the performance of the final product meets the expected standards.
Spraying molding, as another efficient molding method for monolithic refractory materials, is particularly suitable for the repair and reinforcement of existing refractory structures. This process uses high-pressure spraying to evenly spray the refractory slurry on the part to be repaired, thereby forming a continuous refractory layer. Spray forming has significant advantages such as fast construction speed, high flexibility and strong adaptability. It can accurately spray in complex shapes and hard-to-reach areas to ensure the uniformity and continuity of the refractory layer. In addition, this method allows the spray thickness and the type of refractory material to be adjusted according to actual needs to meet different performance requirements.
Vibration forming is a forming method that uses mechanical vibration to closely arrange and combine refractory particles. Under the action of vibration, the refractory particles are subjected to uniform impact force, thereby achieving close stacking and uniform distribution. This method is particularly suitable for manufacturing refractory products with simple shapes and large sizes. Vibration forming has the advantages of high production efficiency, high product density and good dimensional stability. By adjusting the vibration frequency and amplitude, the density and internal structure of refractory products can be accurately controlled to meet different performance requirements.
Pressing forming is a process that presses refractory particles into shape through mechanical pressure. It is suitable for manufacturing refractory products with regular shapes and high dimensional accuracy requirements. During the pressing process, the refractory particles are subjected to uniform pressure, thereby achieving close arrangement and combination. The advantages of this method are regular product shapes, high dimensional accuracy and uniform density. However, press molding has high requirements on molds and is not suitable for the manufacture of refractory products with complex shapes or large sizes.