What are the effects of incomplete or excessive sintering of electrode paste?

Incomplete or excessive sintering of electrode paste can have adverse effects on the quality and performance of electrodes, thereby affecting the operational efficiency and product quality of electric furnaces. Below, we will discuss the possible impacts of these two situations separately:

The impact of incomplete sintering of electrode paste:

Insufficient electrode strength: If the electrode paste is not fully sintered, it will lead to insufficient mechanical strength of the electrode, which is prone to deformation or fracture under high temperature and pressure in the electric furnace.

Reduced conductivity: The unreacted substances inside the electrode paste that have not been fully sintered may affect the conductivity of the electrode, thereby increasing electrical energy loss and reducing production efficiency.

Accelerated electrode consumption: Incomplete sintered electrodes may quickly consume during use, requiring frequent electrode replacement, which increases operational difficulty and cost.

Environmental pollution: Incomplete sintering of electrodes may emit harmful smoke, causing pollution to the environment.

The impact of excessive sintering of electrode paste:

Electrode embrittlement: When the electrode paste is excessively sintered, the electrode may become too hard and lack toughness, and is prone to brittle fracture when encountering sudden temperature changes or mechanical impacts.

Reduced thermal conductivity: Excessive sintering may lead to the formation of excessive non-conductive substances inside the electrode, thereby affecting its thermal conductivity, resulting in uneven temperature distribution around the electrode and affecting product quality.

Slow electrode consumption: Over sintered electrodes may experience slow electrode consumption due to a decrease in conductivity and thermal conductivity, which can prolong production cycles and potentially lead to delays in production plans.

Energy consumption increase: Due to the decrease in conductivity and thermal conductivity, excessively sintered electrodes will consume more electrical energy, thereby increasing production costs.

Therefore, in the production process, sintering conditions should be strictly controlled to ensure that the electrode paste sintering is neither excessive nor incomplete, in order to maintain the stable operation of the electric furnace and the quality of the product.