Fused alumina is a versatile abrasive material that is made by fusing or melting alumina in an electric arc furnace, and has found a wide range of applications in many different industries. It is composed of 94% to 99% alumina and is available in different grain sizes and shapes, depending on the intended use. Fused alumina is known for its high hardness, excellent wear resistance, and good chemical stability.
How is Fused Alumina Made?
The raw materials used to produce fused alumina are bauxite, anthracite, and iron filings. These materials are mixed together in the right proportions and then smelted in an electric arc furnace at a temperature of around 2,000 degrees Celsius. The resulting molten alumina is then cooled and solidified, crushed, and graded into different sizes and shapes.
Properties of Fused Alumina
Fused alumina has several properties that make it useful in different applications. It has a high melting point of around 2,050 degrees Celsius, which makes it ideal for use in high-temperature applications. It is also chemically inert, meaning it does not react with most chemicals. Fused alumina is extremely hard and wear-resistant, making it ideal for abrasive applications.
Classification of Fused Alumina
Brown Fused Alumina
This is the most widely used category of fused alumina, accounting for over 70% of global production. Brown fused alumina is made from bauxite and is characterized by its high toughness and low friability. It’s often used for grinding and cutting applications, as well as in refractory products and abrasive blasting.
This category of fused alumina is made from high-purity alumina and is characterized by its high hardness and toughness. It’s often used in applications that require high-performance abrasives, such as grinding wheels, sandpaper, and cutting tools.
Tabular Alumina
This category of fused alumina is made from high-purity alumina and is characterized by its high temperature resistance and thermal shock resistance. It’s often used in refractory applications, such as for lining high-temperature furnaces.
Black Fused Alumina
This category of fused alumina is made from low iron bauxite and is characterized by its high hardness and low porosity. It’s often used in abrasive applications, such as for grinding and polishing stainless steel and other metals.
Microcrystalline Fused Alumina
This category of fused alumina has smaller crystal sizes than conventional fused alumina, resulting in a material that has improved fracture toughness and wear resistance. It’s often used in cutting tools and other applications that require high strength and durability.
Applications of Fused Alumina
Abrasives
Fused alumina is widely used as an abrasive material due to its high hardness, toughness, and thermal stability. It’s commonly used in grinding and polishing applications, as well as for abrasive blasting in industries such as construction, automotive, and aerospace.
Refractories
Fused alumina is also used in the production of refractory products, which are materials that can withstand high temperatures and harsh environments without degrading. Fused alumina’s high melting point and thermal stability make it an ideal material for use in refractories such as kiln linings, furnace linings, and crucibles.
Ceramics
Fused alumina is used in the production of advanced ceramics due to its high purity, high strength, and excellent thermal and electrical properties. It’s often used in ceramic components for electronic devices, such as substrates, insulators, and circuit boards.
Surface Preparation
Fused alumina is used for surface preparation in industries such as metalworking, construction, and shipbuilding. It’s commonly used for sandblasting and shot peening, which are processes that remove surface contaminants and create a roughened surface for better adhesion of coatings or paint.
Water Filtration
Fused alumina can be used as a filter media in water treatment applications, due to its high porosity and ability to remove contaminants such as heavy metals and organic compounds.
Other Applications
Fused alumina is also used in a variety of other applications, such as in the production of catalysts, cutting tools, and welding electrodes.
Advantages and Limitations of Fused Alumina
The advantages of using fused alumina in different applications are numerous. It has a high hardness and excellent wear resistance, making it ideal for abrasive applications. It is also highly resistant to thermal shock, which makes it ideal for use in high-temperature applications. However, there are some limitations associated with using fused alumina. For example, it is relatively expensive compared to other abrasive materials, and it is difficult to produce in large quantities.
Choosing the Right Fused Alumina for Your Application
There are several different types of fused alumina available, each with different properties and grain sizes. When choosing the right fused alumina for your application, it’s important to consider factors such as the hardness, toughness, and wear resistance of the material, as well as the shape and size of the abrasive grains.
For example, if you need a material with high cutting power and aggressive stock removal, a coarse-grained fused alumina may be the best choice. On the other hand, if you need a material with a fine surface finish, a finer-grained fused alumina may be more appropriate.
Fused Alumina Supplier
Henan Superior Abrasive is a trusted supplier of fused alumina and other abrasive materials. The company has over 20 years of experience in the industry and is known for its high-quality products, competitive prices, and excellent customer service.
Henan Superior Abrasive produces a wide range of fused alumina products, including brown fused alumina, white fused alumina, and tabular alumina. These products are available in various sizes and shapes to meet the needs of different applications. The company’s products are manufactured using advanced production techniques and undergo rigorous quality control to ensure consistent quality and performance.
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