Short Lifespan of Brick Machine Molds? 3 Tips to Choose the Right Wear-Resistant Materials
In the production of concrete blocks and refractory bricks, molds are one of the most vulnerable parts and represent the largest operating cost of production equipment. The root cause of brick machine mold wear lies in abrasive wear—hard particles in the brick material (such as quartz, feldspar, etc.) rub intensely against the mold surface during the molding process, causing the surface material to gradually peel off. When the mold surface wear reaches 0.3-0.4mm, the brick blank dimensions will be out of tolerance, resulting in quality problems such as cracks, chipped edges, and corner damage, necessitating replacement or repair. So, how can we solve the problem of short mold lifespan from the material perspective? The following three tips will help you choose the right wear-resistant materials.
Tips 1: Understand the "Levels" of Mainstream Mold Materials
The most crucial requirement for brick machine mold materials is wear resistance, while strength, toughness, and process feasibility must also be considered. Currently, mainstream mold materials can be divided into three levels:
Entry-level:Carbon steel and alloy steel: Represented by low and medium carbon steel, surface hardness is improved through gas carbonitriding heat treatment (reaching HRC 60-64). They are inexpensive and widely used, but their lifespan is relatively limited. These materials are suitable for small- to medium-scale production with small batch sizes.
Advanced-level:High-chromium alloys and mold steels: Such as high-chromium alloy steel and high-chromium cast iron, their wear resistance is significantly better than ordinary carbon steel. Comparative studies have found that H13 steel exhibits excellent wear resistance among hot-work mold steels. These materials are suitable for medium to large-sized brick factories with specific requirements for mold lifespan.
High-end:Hard alloys and steel-bonded hard alloys: This is currently recognized as the best wear-resistant solution. GT35 steel-bonded hard alloy is particularly noteworthy—it uses steel as the binder phase and titanium carbide as the hard phase, combining the machinability of tool steel with the high hardness of hard alloys (HRC can reach 68-72 after heat treatment), with a density of only 6.4 g/cm³, and can be used to manufacture complex, irregularly shaped molds.
The Second Strategy: Carbide Inlay – The Secret to 60-100 Times Longer Lifespan
If choosing high-grade materials is an "upgrade," then carbide inlay technology is a "qualitative leap."
Inlay Process: A 10-200mm thick tungsten carbide alloy block (such as YG15) or steel-bonded carbide block (such as GT35) is inlaid into the worn areas of the mold. After adhesive bonding and precision grinding, it is installed into the mold frame for use.
Lifespan Comparison: Research data from Science Popularization China shows that the lifespan of carbide-inlaid molds is 60-100 times longer than that of ordinary carbon steel molds. Furthermore, after each wear event, the marks can be ground away and the mold can be reassembled for reuse, with a single mold piece being reusable approximately 10 times.
Although carbide materials are expensive, the unit production cost is actually lower – making it especially suitable for high-volume, long-term continuous production scenarios.
The Third Strategy: The "Nice Finishing Touch" of Process and Design
Besides choosing the right material, process and design can also significantly extend mold lifespan:
Surface Strengthening Treatment: Surface treatments such as carbonitriding and chromium infiltration on ordinary steel molds can significantly improve surface hardness. Studies have reported that the service life of chromium-infiltrated cast iron brick-making molds is 8-10 times that of modified cast iron molds.
Mold structure optimization: For example, moving the brick forming position of the brick press upwards allows the mold to be reused after wear, with each side usable twice, effectively extending its lifespan. This approach also applies to the layout design of the mold's inlaid alloy blocks—placing the alloy blocks in the areas of highest wear to maximize material utilization.
Reusing used molds: Severely worn but not yet scrapped molds can be re-ground or have their inlaid blocks replaced for continued use, reducing the cost of purchasing new molds.
Extending the lifespan of brick machine molds hinges on selecting the right materials, using the right processes, and designing correctly. For brick factories with large-scale, continuous production, directly choosing hard alloy inlaid molds, although requiring a higher initial investment, is the optimal solution for cost reduction in the long run. For small- to medium-scale production, high-chromium alloys combined with surface strengthening treatment are a pragmatic choice that balances cost-effectiveness. Choosing the right mold material is crucial to truly addressing your "lifespan shortcoming."
