What is Medium Grain Graphite Block
Medium grain graphite blocks are used for roughing and finishing applications and have a grain size of 0.020 in up to 0.062 in (0.508 mm up to 1.5748 mm) with 12% to 20% of the volume of the blocks being porous and are visible with the naked eye due the particles being the base material.Graphite blocks are a crystalline form of carbon that are engineered to have special properties such density, electrical resistance, hardness, porosity, compressive strength, flexural strength, thermal expansion, and thermal conductivity.
Advantages of Medium Grain Graphite Block
Strong conductivity
Graphite blocks are excellent conductors, suitable for various electrical and electronic applications. They exhibit good electrical and thermal conductivity, thus finding wide use in batteries, electrolytic cells, conductive lubricants, and more.
High chemical stability
Graphite blocks demonstrate stability in many chemical substances, resisting acids, alkalis, solvents, etc., making them extensively used in the chemical industry.
Good mechanical properties
Graphite blocks possess a certain level of strength, hardness, and elasticity, enabling them to withstand certain pressures and abrasion in mechanical applications.
Excellent high-temperature resistance
Graphite blocks maintain stability at high temperatures, resisting thermal stress and thermal shock.
Good lubrication properties
Graphite blocks act as effective lubricants at high temperatures, serving as lubricating additives, for instance, in manufacturing mechanical components.
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Henan daking import and export co., ltd. Is one of china's professional production, research and development, sales of graphite mold manufacturers. The company is committed to providing customers with high quality graphite raw materials and precision graphite products processing.
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Graphite mold, graphite crucible, graphite sagger, graphite plate, graphite block, graphite rod, graphite tube, graphite box, graphite electrode, diamond sintering mold, heat treatment vacuum furnace graphite accessories, photovoltaic semiconductor industry graphite parts, graphite heater for monocrystalline silicon, various special-shaped graphite accessories, etc.
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Graphite Block Grain Sizes
Fine grain graphite
Fine grain graphite has high density that produces precision machined details with exceptional finishes, a factor that reduces wear. For a graphite block to be designated as fine grain, its material has particles that range in size from 0.0001 in up to 0.005 in (0.00254 mm up to 0.127 mm) with the grains having been milled to achieve the particle size and pressed into the graphite block shape. Approximately 5% to 15% of the volume of fine grain graphite is made up of openings between the particles that are hard to see due to their very small size. Since fine grain graphite is very dense, it is very commonly produced in small cross sectional blocks.
Medium grain graphite
Medium grain graphite blocks are used for roughing and finishing applications and have a grain size of 0.020 in up to 0.062 in (0.508 mm up to 1.5748 mm) with 12% to 20% of the volume of the blocks being porous and are visible with the naked eye due the particles being the base material. The production of medium grain blocks is less expensive and does not involve the use of isostatic molding but is completed using extrusion or compression molding. Medium grain graphite is used to produce furnaces, trays, extrusion guides, heating elements, crucibles, and self-lubricating bears, which is one of its major uses.
Coarse grain graphite
Coarse grain graphite is an economical solution for processes that require large amounts of raw materials. The grain size for coarse grain graphite ranges between 0.040 in and 0.25 in (1.016 mm and 6.35 mm) with porosity ranging between 12% and 20%. Coarse grain graphite is prized for the manufacture of crucibles, large ingot molds, and pouring troughs due to its ability to handle thermal shock and rapid changes in temperature from molten metals. The very large particles of coarse grain graphite are easily visible to the naked eye. The strength and stability of coarse grain graphite makes it ideal for forming large parts.
How Are Medium Grain Graphite Block Made?
Raw material selection
The first step in making graphite blocks is selecting the raw materials. High-quality graphite starts with high-purity carbon. Typically, natural graphite is used, which is mined from graphite deposits. Synthetic graphite, produced from petroleum coke or pitch coke, is another option. The choice depends on the specific requirements of the application and the desired properties of the final product.
Purification
Regardless of the source, the raw graphite undergoes purification to remove impurities and achieve the desired level of purity. Purification methods may include chemical treatments, thermal processes, and mechanical purification techniques. These processes eliminate contaminants and enhance the material's structural integrity and thermal conductivity.
Mixing and blending
Once purified, the graphite powder is mixed with binders and additives. Binders help hold the graphite particles together during shaping and initial stages of processing. Additives may include substances that improve the material's properties, such as strength, density, or thermal conductivity. The precise composition of the mixture depends on the intended application and performance requirements.
Shaping
The mixed graphite blend is then shaped into blocks through a process known as compression molding. In this method, the graphite mixture is placed into a mold cavity and subjected to high pressure. The pressure compacts the mixture, squeezing out excess air and ensuring uniform density throughout the block. Various techniques, such as hydraulic pressing or extrusion, may be employed depending on the desired shape and dimensions of the final product.
Thermal treatment
After shaping, the green graphite blocks undergo a series of thermal treatments to further enhance their properties. The blocks are heated to high temperatures in a controlled atmosphere or vacuum environment. This process, known as graphitization, transforms the amorphous carbon structure into a crystalline graphite structure, improving thermal and electrical conductivity while reducing porosity.
Machining and finishing
Once graphitized, the blocks are machined to achieve precise dimensions and surface finishes. Machining processes such as milling, drilling, and grinding are employed to shape the blocks according to specific requirements. Careful attention is paid to maintain tight tolerances and surface quality to ensure optimal performance in the final application.
Quality control
Throughout the manufacturing process, rigorous quality control measures are implemented to ensure that the graphite blocks meet the required standards and specifications. Quality checks may include dimensional inspections, density measurements, material composition analysis, and mechanical testing. Any deviations from the desired parameters are identified and addressed promptly to maintain product consistency and integrity.
Application-specific processing
Depending on the intended use, additional processing steps may be required to tailor the graphite blocks to specific applications. For instance, in nuclear reactors, the blocks may undergo further treatments to achieve desired neutron-absorbing properties or to accommodate thermal expansion requirements.
Final inspection and packaging
Once the graphite blocks have undergone all necessary processing steps, they undergo final inspection to verify compliance with quality standards. Blocks that meet the specifications are carefully packaged to prevent damage during transportation and storage. Proper labeling and documentation ensure traceability and facilitate integration into the final assembly or installation.
High thermal conductivity: Graphite is an excellent conductor of heat. The hexagonal arrangement of carbon atoms allows for efficient heat transfer within the material. This property makes graphite blocks suitable for applications where thermal management is crucial, such as in the manufacturing of crucibles, as mentioned in the previous response.
High electrical conductivity: Similar to its thermal conductivity, graphite exhibits high electrical conductivity. This property is exploited in applications where electrical conductivity is essential, such as in electrodes for electric arc furnaces, electrical discharge machining (edm), and other electrical applications.
Lubricating properties: The layered structure of graphite also gives it lubricating properties. The weak forces between the layers allow them to slide over each other easily. This self-lubricating characteristic makes graphite blocks suitable for applications where reduced friction and wear are essential, such as in certain types of bearings and seals.
Chemical inertness: Graphite is chemically inert, meaning it does not easily react with other substances. This property makes graphite blocks resistant to corrosion and degradation in harsh chemical environments. It is commonly used in applications involving corrosive chemicals, including as a lining material for chemical reactors and as a component in certain types of gaskets and seals.
High melting point: Graphite has an exceptionally high melting point, around 3,500 degrees celsius (6,332 degrees fahrenheit). This high melting point makes graphite blocks suitable for use in high-temperature applications, such as in the production of crucibles and as a structural material in high-temperature furnaces.
Low thermal expansion: Graphite exhibits low thermal expansion, meaning it does not significantly change in volume with changes in temperature. This property is valuable in applications where dimensional stability is crucial, such as in molds and dies used in high-temperature processes.
Mechanical strength: While not as strong as some metals or ceramics, graphite blocks have sufficient mechanical strength for many applications. They can withstand compressive and shear forces and are often used in structural components for high-temperature environments.
High melting point: Graphite has an exceptionally high melting point, around 3,500 degrees celsius (6,332 degrees fahrenheit). This high melting point makes graphite blocks suitable for use in high-temperature applications, such as in the production of crucibles and as a structural material in high-temperature furnaces.
Low thermal expansion: Graphite exhibits low thermal expansion, meaning it does not significantly change in volume with changes in temperature. This property is valuable in applications where dimensional stability is crucial, such as in molds and dies used in high-temperature processes.
Mechanical strength: While not as strong as some metals or ceramics, graphite blocks have sufficient mechanical strength for many applications. They can withstand compressive and shear forces and are often used in structural components for high-temperature environments.
Lightweight: Graphite is a lightweight material. Its low density makes graphite blocks suitable for applications where weight is a critical factor, such as in aerospace components and certain types of structural elements.
Good machinability: Graphite is relatively easy to machine, allowing for the production of complex shapes and precision components. This property enhances its versatility in various manufacturing processes.
Non-toxic and biocompatible: Graphite is generally non-toxic and biocompatible, making it suitable for certain medical and biotechnological applications. For example, graphite is used in some medical implants and diagnostic devices.
Application of Medium Grain Graphite Block
Powder metallurgy
In powder metallurgy, graphite blocks are used in sintering where raw materials are placed on a graphite block and melted. The high temperature and oxidation resistance of graphite blocks meets the demanding requirements of the powder metallurgy industry. The blocks can be used repeatedly, which saves users the cost of production.
Foundry industry
Metals can be heated in a graphite crucible up to 2732°f (1500°c) to convert metals into liquid form for graphite mold casting, a method that can be used to cast all forms of industrial products. Graphite molds are similar to metal molds and have good thermal conductivity and thermochemical stability. Castings using tin bronze and aluminum iron bronze use graphite molds to eliminate casting defects like shrinkage, porosity, and pinholes with the added benefit of better mechanical properties.
Electrodes
Graphite blocks used for the manufacture of electrodes have high electrical conductivity and refractory properties such as thermal shock resistance and low thermal expansion. They are the only products that are able to endure the necessary electrical conductivity for electric arc furnaces and endure the high levels of heat.
Nuclear fusion
Synthetic graphite blocks are most commonly used for moderators or reflectors for nuclear reactors. For uranium fission to occur properly, the neutrons created have to be slowed down by a neutron moderator, an element with low atomic weight. Initially, heavy water was used but was replaced by graphite with very high purity. Graphite blocks for nuclear fusion have to be of the highest purity and be free of boron, which absorbs neutrons.
How to Cut Medium Grain Graphite Block
The synthetic graphite blocks’ first stop beyond the storage warehouse is almost always the saw department. Here, large blocks or rounds of synthetic graphite are trimmed and partitioned based on each job’s specifications. Since virtually all material used in the facility passes through one of our saws, we naturally make safety in our saw department a priority. By implementing various safety features, we enable our operators to cut material safely.
Dust port: This feature channels dust away from the cutting platform and is connected to our dust collector. Dust ports enable dust free operations, better visibility, and good air quality.
Blade adjustment knob: This knob helps adjust the cutting blade’s height and position. Allowing the machinist to set the blade at the proper height accommodates the safe handling of specific blocks, which come in many sizes.
Blade: We choose from various blade types, from diamond to carbide. Each choice of blade compound is determined for the specific material grade to be cut, and ensures that the material is cut cleanly and efficiently.
Wheel guard: This component guards the saw’s wheel inside the frame since the wheel is sharp and can easily cause accidents if left exposed.
Blade guard: This component guards the spinning blade to prevent an accident or kickback during the job.
Blade tensioner: The usefulness of this component is in safely ensuring that the blade isn’t too tight when working with softer material. If the blade is too tight, it can cause breakage or possibly slip off the wheels.
Henan Daking Import and Export Co., Ltd. (Henan Daking for short) is one of China's professional production, research and development, sales of graphite mold manufacturers. The company is committed to providing customers with high quality graphite raw materials and precision graphite products processing. The raw materials used by our company, such as isostatic pressed graphite, molded graphite and EDM graphite, have the characteristics of high strength, good thermal shock resistance, high temperature resistance, corrosion resistance and strong oxidation resistance.
FAQ
We're professional medium grain graphite block manufacturers and suppliers in China, specialized in providing high quality customized service. We warmly welcome you to buy high-grade medium grain graphite block made in China here from our factory.
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