The AZS working face does not undergo mechanical processing, and its core benefits are to retain the original dense layer of melting and casting, improve corrosion resistance and thermal shock stability, reduce costs and processing risks, especially suitable for key high-temperature parts.
1. Retain the native dense layer to maximize erosion resistance
→Optimal primary surface layer: After cooling by electric melting AZS casting, a dense, low porosity, and defect free primary surface layer is formed on the working surface (with a porosity close to 0), which is the area with the strongest resistance to glass liquid/slag erosion.
→Processing damages the protective layer: Mechanical processing (cutting, polishing) will remove this dense skin layer, exposing the relatively loose substrate inside, directly reducing the corrosion resist.
→Reduce glass liquid pollution: The original surface is purer, without processing microcracks and dust residue, reducing the risk of stones and bubbles in the glass liquid, and ensuring the quality of high-end glass.
2. Avoid processing damage, improve thermal shock and structural stability
→Eliminating processing stress: AZS has extremely high hardness (Mohs 9), which can easily cause microcracks, hidden cracks, lattice distortions during processing, and can easily expand at high temperatures, leading to explosions and peeling.
→Maintain overall strength: Without processing, the original structural strength and thermal shock stability of the brick can be fully preserved, reducing safety hazards during kiln operation.
→Reduce shrinkage/porosity exposure: Processing may cut into internal shrinkage and porosity areas, forming erosion channels. Without processing, avoid these weak points.
3. Significantly reduce costs and increase efficiency, shorten delivery cycles
→Save processing costs: AZS processing requires specialized diamond/hard alloy cutting tools, a large amount of coolant, low efficiency, high tool wear, and high energy consumption. Not processing can save all processing costs.
→Reduce material loss: Processing allowance (3-10mm) will result in high-value AZS material waste, without processing, there will be zero loss.
→Shorten production cycle: eliminate cutting, polishing, inspection and other processes, deliver faster, and adapt to the needs of kiln repair and rapid production.
4. Simplify construction and improve masonry quality
→Reduce on-site maintenance: The flatness and dimensional accuracy of the original working surface are controllable, and there is no need for secondary processing on site, reducing construction difficulty and dust pollution.
→Optimize the sealing of brick joints: Retain the natural casting surface, make the brick joints easier to seal, reduce the risk of material leakage and fire, and improve the airtightness and thermal efficiency of the kiln.
Summary: Applicable scenarios and precautions
Priority not to process: glass kiln pool bottom, pool wall, flow hole, clarification section and other strong erosion and critical parts.
Localized processing: Non working surfaces, installation positioning surfaces, and special shaped interfaces can be processed in small quantities, but the working surface can retain the original layer.
Prerequisite: The casting process needs to control the dimensional tolerances and surface quality to ensure that it meets the masonry requirements without processing.
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