Step 1: Raw Material Quality Control

Before production begins, we verify the foundation of our ceramics:

• Particle Size: Analyzed via laser particle size analyzer.
• Moisture Content: Checked with halogen moisture analyzer.
• Bulk Density & Compression: Verified using precision balance and pressure test methods.
• Glue Content: Precisely measured to ensure binding integrity during forming.

Step 2: Forming Process

Depending on the geometry of the bead mill part (e.g., grinding discs vs. rod pins), we select the optimal forming method:

• Die Pressing Process: For standard shapes requiring high density.
• Isostatic Pressing Process: For uniform density in complex or large components.
• Micron Precision Injection Molding: For complex geometries mentioned in our company capabilities.

Step 3: Green Process & Pre-Sintering

Before final hardening, parts are shaped to near-net form:

• Forming by Turning: Initial shaping of the green body.
• Trimming & CNC Precision Carving: Removing excess material and defining critical features before sintering shrinks the part.

Step 4: Sintering Process (The Heart of Durability)

This is where the ceramic achieves its final mechanical properties:

• Equipment: Gas kilns and Electric kilns.
• Control: Different sintering curves are used for different materials. This ensures the Y8, 3Y, or Yellow Zirconia series achieves its specific grain structure and toughness.
• Temperature: High-temperature sintering (typically 1500°C+ for zirconia) to achieve >99.5% theoretical density.

Step 5: Fine Machining & Finishing

Sintered zirconia is extremely hard (≥1200 HV), requiring diamond tooling for final precision:

• Vertical & Flat Mill: For height and surface grinding.
• Inside & Outside Grinding: For precise inner/outer diameters.
• CNC Machining: Specifically for special-shaped products or products with high precision requirements (e.g., complex grinding discs).
• Drilling & Milling: For products with lower precision requirements.

Success Story:

A leading global battery materials manufacturer was experiencing excessive wear in their horizontal bead mills, leading to frequent downtime and potential iron contamination. After switching to CRAC's Y-ZR (3Y Series) grinding discs and turbines:

• Service Life: Extended by over 5 times compared to previous ceramic suppliers.
• Purity: Metal contamination levels dropped to undetectable limits, passing strict quality audits.
• Efficiency: Stable dimensional accuracy allowed for higher operating speeds without vibration.

Ceramic-Metal Bonding: We can provide ceramic and metal bonding services using epoxy resin or ceramic adhesive bonding methods, allowing for hybrid components where needed.

✅ Do they control raw material properties?

CRAC: Yes. We test particle size, moisture, bulk density, and glue content before production begins.

✅ Can they handle high-precision machining?

CRAC: Yes. We utilize CNC machining for special-shaped products with cylindricity reaching 0.005mm.

✅ Do they perform non-destructive testing?

CRAC: Yes. Specific products undergo Red or UT nondestructive testing to ensure structural integrity.

✅ Do they have a proven track record?

CRAC: Yes. Established in 2006 (tech dev since 1997), serving over 100 central/state-owned/listed enterprises globally.

✅ Can they provide custom solutions?

CRAC: Yes. We offer process design management including mold design, fixture design, and CNC program sheets.

Q: What types of zirconia materials do you offer for bead mills?

A: We offer four main categories: A-ZR (Y8 Series) for dry grinding, Y-ZR (3Y Series) for general high-wear applications, PR-ZR (Yellow Zirconia) for high toughness, and Composite Ceramics for specialized needs.

Q: What is the maximum size of a grinding disc you can produce?

A: For disc-type products, we can handle a maximum outer diameter of 550mm and a maximum inner diameter of 500mm, with a maximum milling product height/depth of 200mm.

Q: Can you bond ceramic parts to metal components?

A: Yes. We provide ceramic and metal bonding services using epoxy resin or ceramic adhesive bonding methods, useful for assemblies requiring both materials.

Q: How do you ensure the parts won't crack under high-speed agitation?

A: Our Fracture Toughness is ≥11 MPa.m¹/² (for Y8/3Y series), and we perform UT nondestructive testing on specific products to detect internal flaws before shipment.

Q: Do you support custom design and molding?

A: Yes. Our Process Design Management includes Design Mold, fixture, grinding, and CNC program sheets tailored to your specific drawings.

Q: What industries currently use your bead mill parts?

A: Our parts are widely used in electrode materials, nanomaterials, inks, pharmaceuticals, chemicals, and ceramics.

Q: Where is your company located?

A: We are located at 100 meters east of the intersection of Chuangye Road and Xiangquan Road, Tianyuan District, Zhuzhou City, Hunan Province, China.

Q: How can I request a quote or technical support?

A: You can contact us via email at crac@crac-cn.com or call +86-0731-28813608.