Low cement (LC) and ultra low cement (ULC) bauxite SiC castables are important and high performance monolithic refractories and they have been widely used in iron making and incinerator linings. In this work, rheol...Low cement (LC) and ultra low cement (ULC) bauxite SiC castables are important and high performance monolithic refractories and they have been widely used in iron making and incinerator linings. In this work, rheological behavior of LC and ULC bauxite based SiC containing castables has been studied, including the effects of SiC content and cement content on rheological properties of the castables. The results show that with an increase of SiC and cement content, rheological properties of the castables deteriorate. On the other hand, moderate amounts of SiC (4%～8%) and of calcium aluminate cement (2%～4%) have very slight influence on rheological properties, (i.e. when the castables are sheared their torque and yield torque only slightly increase with the shearing speed). The rheological characteristics of the castables follow Bingham fluid and always show shear thinning behavior.展开更多
High-performance alumina-magnesia castables were developed with the addition of nano-CacO_(3) and nano-hydromagnesite.To further understand their dynamic failure mechanism,the quantitative investigation via the employ...High-performance alumina-magnesia castables were developed with the addition of nano-CacO_(3) and nano-hydromagnesite.To further understand their dynamic failure mechanism,the quantitative investigation via the employment of the Split-Hopkinson pressure bar(SHPB)method was adopted to test the dynamic failure behavior of alumina-magnesia castables under various impact velocities.The results demonstrate that the greater the impact velocity,the more intense the sample damage.The dynamic compressive stress,the ultimate strain,and the strain energy of all samples display a strain rate hardening effect,and this phenomenon is more conspicuous in the samples incorporating nano-additives.The nano-additives show a positive influence on the dynamic mechanical properties of the castables.展开更多
In order to improve the service performance of Al_(2)O_(3)-SiC-C castables,a novel Si-N-O composite micropowder was synthesized by the chemical combustion method.Using brown corundum,sintered alumina,silicon carbide,a...In order to improve the service performance of Al_(2)O_(3)-SiC-C castables,a novel Si-N-O composite micropowder was synthesized by the chemical combustion method.Using brown corundum,sintered alumina,silicon carbide,activeα-Al_(2)O_(3)micropowder,SiO_(2)micropowder,calcium aluminate cement,Si powder and spherical asphalt as the raw materials,adding additive of Si-N-O composite micropowder,Al_(2)O_(3)-SiC-Si_(3)N_(4)/Si_(2)N_(2)O-C castables were prepared.The effects of the Si-N-O composite micropowder addition on the mechanical properties and oxidation resistance of the castables were investigated,and the intrinsic mechanism of strengthening and antioxidation caused by this novel additive was discussed.Experimental results show the introduction of Si-N-O composite micropowder leads to significant improvement in the cold strength,oxidation resistance,thermal shock resistance and hot modulus of rupture of the Al_(2)O_(3)-SiC-C castables.When the Si-N-O composite micropowder addition is approximately 3 mass%,the castable possesses the best comprehensive performance.展开更多
The penetration of ladle slag into refractory linings is an essential process in service,and the mechanical properties of the refractory castables are affected by the location and content of slag in the refractory cas...The penetration of ladle slag into refractory linings is an essential process in service,and the mechanical properties of the refractory castables are affected by the location and content of slag in the refractory castables.In this work,ladle slag was added into Al_(2)O_(3)-Mgo refractory castables and its influence on the microstructure evolution,mechanical properties and thermal shock resistance of the castables was investigated.The phase composition and contents of the castables during the corrosion process were calculated by FactSage TM(6.2)and studied.The results indicate that the residual strength decreases as the ladle slag addition increases from 0 to 6 mass%.While the hot modulus of rupture of the castable with 6%ladle slag significantly decreases by approximately 80%compared with the one without ladle slag.The elastic modulus and CMOR of the castables decrease with slag-adding,which leads to the increase of liquid phase contents inside the samples.展开更多
In order to prolong the working time of calcined flint clay-bauxite castables during construction at high temperature,boric acid was added into the castables. The effect of boric acid on working time and curing cold c...In order to prolong the working time of calcined flint clay-bauxite castables during construction at high temperature,boric acid was added into the castables. The effect of boric acid on working time and curing cold crushing strength of the castables at 25 ℃ and 35 ℃ were investigated. After 24 h curing in mould and another 24 h curing at 110 ℃ after demoulding,the specimens were heat treated at 1 000 ℃,1 300 ℃,and 1 500 ℃ for 3 h,respectively. The permanent linear change,bulk density,modulus of rupture,and cold crushing strength were determined. The result shows that there is no need to add boric acid when calcined flint clay-bauxite castables works at 25 ℃; when calcined flint clay-bauxite castables works at 35 ℃,boric acid can increase the working time of the castables,but decrease the curing cold crushing strength a little. Adding boric acid into calcined flint clay-bauxite castables doesn＇t worsen performance of the castables.展开更多
Thermal behavior and physical properties of castables during curing and drying-out are associated with their binding system. In this work, five alumina based （ Al2O3 〉 87% ） castables with different combinations of...Thermal behavior and physical properties of castables during curing and drying-out are associated with their binding system. In this work, five alumina based （ Al2O3 〉 87% ） castables with different combinations of binding materials, i. e. , （ 1 ） CA cement （CA） ＋ Reactive alumina （ RA ） ＋ H2O ; （ 2 ） high level addi- tion of CA ＋ Microsilica （MS） ＋ H2O ; （ 3 ） low level addition of CA ＋ MS ＋ H2O ; （4） MS ＋ Hydratable alumina ＋ H20 and （ 5 ） MS ＋ Magnesia ＋ H2O, respectively, have been investigated on the flowability and thermal behavior during curing at room temperature, drying at 110% and heating from 200℃ to 1000℃ at an interval of 100℃ , in terms of water addition, vibration flow value, porosity, dehydration, explosion resistance, cold and hot bending strengths. Differences in dehydrating behavior and the mentioned properties have been revealed and correlated to the binding system.展开更多
Microsilica-gel bonded bauxite based no-cement refractory castables（NCCs）have been produced using two readily available dispersants.These NCCs were compared to NCC with Siox X-Zero,a purposely-developed product for ...Microsilica-gel bonded bauxite based no-cement refractory castables（NCCs）have been produced using two readily available dispersants.These NCCs were compared to NCC with Siox X-Zero,a purposely-developed product for microsilica-gel bonded no-cement castable systems to control flow properties and setting characteristics.Three mixing and curing temperatures were applied：5℃,20℃and 35℃.The results show that setting-behaviour and mechanical properties strongly vary with the type of dispersant and the curing temperature.However,both setting and strength are less temperature dependent in the castables with Siox X-Zero.Furthermore,the drying and firing of microsilica-gel bonded NCCs were investigated.Since microsilica-gel bond system contains only a small amount of bound water,the castables can be fired at very high heating rates,once the free water has been removed.展开更多
The castables specimens were prepared using white fused alumina particle and powder, α-Al2O3 micropowder, hydrated alumina, nano calcium carbonate or calcium aluminate cement as starting materials. Effects of nano ca...The castables specimens were prepared using white fused alumina particle and powder, α-Al2O3 micropowder, hydrated alumina, nano calcium carbonate or calcium aluminate cement as starting materials. Effects of nano calcium carbonate addition on phase compositions, strength and microstructure of corundum based castables were studied. The calcium aluminate cement-containing corundum based castables with the same CaO amount was also tested for comparison. The results show that, when temperature is higher than 900 ℃ , the phase compositions of nano CaCO3-containing mixture and the calcium aluminate cement containing mixture are the same, but the forming mechanism, modality and distribution of new phases in the castables are different. With temperature rising, the hydration cement dehydrates and reacts inside cement forming calcium aluminate until the alumina in cement is not enough for the reaction （ternperature is 91 400 ℃ ） , then reacts with the surrounding alumina forming cluster CA6 in the castables. The change process of nano CaCO3 in corundum based enstables is that nano calcium carbonate decomposes to CaO after firing at 800℃ which reacts with Al2O3 forming amorphous calcium aluminate that causes an in-situ bonding. With temperature rising, the formed calcium aluminate reacts with Al2O3 in matrix and wholly forms tabular CA6 at 1 600 ℃ , which distributes uniformly in the castables. The cold and hot strength of the castables with nano calcium carbonate are obviously higher than those of the castables without nano calcium carbonate, especially at 800 -1 000 ℃ due to smaller size and higher dispersion of the nano calcium carbonate and its different reaction mechanism with Al2O3.展开更多
A series of corundum based castables with 0,2%,4%,6%,and 8% α-Al2O3 micropowders were prepared using tabular alumina aggregates （6-3,3-1 and ≤1 mm） and fines （≤0.088 and ≤0.045 mm）,calcium aluminate cement,and...A series of corundum based castables with 0,2%,4%,6%,and 8% α-Al2O3 micropowders were prepared using tabular alumina aggregates （6-3,3-1 and ≤1 mm） and fines （≤0.088 and ≤0.045 mm）,calcium aluminate cement,and α-Al2O3 micropowders （d50=1.754 μm） as starting materials. Cold mechanical strength and pore size distribution of the castables specimens after heat treatment at 110,1 100 and 1 500 ℃ were tested,respectively. The quantitative relationship between strength and apparent porosity,and that between strength and median pore diameter were verified by Atzeni equation. The correlation between interval of pore size and mechanical strength of specimens was also studied by means of gray relational theory. The results show that：（1） the pore size distribution of castables is strongly influenced by both micropowders filling and matrix sintering; the addition of micropowders decreases median pore diameter while the sintering process increases it; （2） when adding a constant correction term,Atzeni equation can substantially describe the quantitative relationship between median pore diameter and strength of castables specimens after heat treatment at the same temperature; the significant differences of the gray relational degree between the interval of pore size and castables strength are characterized; it is also found that for the same interval of pore size,the gray relational degree isaffected by the heat treatment temperature; the pore size interval 〈0.5 μm has the highest gray relational degree with the strength at 110-1 500 ℃.展开更多
In this study, the properties of self-flowing ultra-low cement castables in Al2O3-SiC-C system have been investigated and compared to vibration castables. The major physical and mechanical properties, microstructure a...In this study, the properties of self-flowing ultra-low cement castables in Al2O3-SiC-C system have been investigated and compared to vibration castables. The major physical and mechanical properties, microstructure and corrosion behavior of these castables against slag have been evaluated. The results showed that the microstructure of Al2O3-SiC-C self-flowing castable is more uniform than the vibrated structure. Also self-flowing castable has smaller pore size and more uniform pore size distribution. Hence, density, strength, oxidation and slag resistance of the self-flowing castables is higher than that of vibration castables. Therefore, besides other benefits such as noise free, easy installation, fewer mold defects and reduced installation costs, Al2O3-SiC-C self flowing ultra low cement castables will have longer service life in comparison with vibration casables.展开更多
The properties and microstructure of sol self-clean bonded Al2O3-SiC-C castable in iron runner were studied, and the relation between the amount of sol self- clean binder and the properties of castable were discussed....The properties and microstructure of sol self-clean bonded Al2O3-SiC-C castable in iron runner were studied, and the relation between the amount of sol self- clean binder and the properties of castable were discussed. It is believed that the addition of sol self-clean binder can improve the compressive strength, but has little effect on the bulk density and the apparent porosity, which enable the castable to be applicable in different conditions.展开更多
CMA72 bonded Al2 O3 - MgO castable is promising for application of steel ladle wall, because of unique combination of thermo-mechanical properties, slag corro- sion resistance and cost benefit. In these castables, mi-...CMA72 bonded Al2 O3 - MgO castable is promising for application of steel ladle wall, because of unique combination of thermo-mechanical properties, slag corro- sion resistance and cost benefit. In these castables, mi- crosilica can be introduced to counterbalance the expan- sion generated by spinel formation. In this paper, the of microsilica dosage on properties of eastables was evaluated. Expansion, expressed by the permanent linear change （PLC）, is highly dependent on the dosage of microsilica. Unexpected expansion occurs when the dos- age of microsilica is too low due to dominant effect of spinel and CA6 formation. Too high dosage results in sintering shrinkage, which is related to amount of liquid phase generated by microsilica addition. In addition, HMOR declines dramatically with increasing microsilica dosage. Considering the balance between expansion con- trol and hot property retention, 1.0 mass% of microsili- ca is recommended for the castable containing 4 mass% of magnesia.展开更多
Magnesite fine powder, natural silica powder,light-burned magnesia fine powder, silica fume and middle grade magnesia fine powder were used as the starting materials,and silica sol as binder to get high purity lightwe...Magnesite fine powder, natural silica powder,light-burned magnesia fine powder, silica fume and middle grade magnesia fine powder were used as the starting materials,and silica sol as binder to get high purity lightweight spherical forsterite aggregates. The mixture was granulated on a disc pelletizer and then calcined at 1 400 ℃ for 3h. The synthesized spherical forsterite aggregates were added in Mg O based castables with MgO-SiO2-H2O binding system to replace equaldensity high purity common forsterite aggregates. Effect of spherical forsterite aggregates addition on properties of MgO based castables was investigated. The results show that: compared with common aggregates,lightweight spherical forsterite aggregates can improve castables ’flow ability and decrease water addition; addition of spherical aggregates has little effect on cold strength of castables; with the increase of spherical aggregate addition,shrinkage of specimens after drying and heating at intermediate temperatures decreases,but the expansion of specimens after heating at high temperatures increases,bulk density decreases and apparent porosity increases,and thermal conductivity declines.展开更多
Compared with traditional aggregates,spherical aggregates with high flowability,easy control of particle size distribution and favor of dense packing and so on,are expected to replace traditional aggregates as importa...Compared with traditional aggregates,spherical aggregates with high flowability,easy control of particle size distribution and favor of dense packing and so on,are expected to replace traditional aggregates as important raw materials for future high performance refractories. Therefore,investigation of effects of spherical aggregates addition on properties of refractories becomes very meaningful. Using A70 mullite traditional aggregates and A70 mullite spherical aggregates, bauxite homogenization powder,microsilica,and calcium aluminate cement as raw materials,different AlO-SiOsystem low cement castables were prepared by replacing conventional aggregates with spherical aggregates. The effect of spherical aggregates addition on workability and mechanical properties of castables after heated at different temperatures was researched,and microstructure of the specimen was analyzed by SEM. Compared with traditional irregularly shaped aggregates,spherical aggregates endow castables with better flowability and easy pump ability. By introduction of spherical aggregates into the castables,flowability and pumpability are significantly improved,and water addition and ball completely sunk time are reduced. The introduction of spherical aggregates is favorable to density and cold crushing strength of castables,but unfavorable to CMOR. The effect of spherical aggregates addition on HMOR at1 400 ℃ can be negligible. Microstructure analysis showsthat the boundary bonding between spherical aggregates and matrix is strong,similar to the traditional aggregates.展开更多
Installation of refractory castables depend not only on flow , but also on how soon the flow is lost because of setting. The loss of flow (flow decay) has always been one of the main problems of refractory castable ma...Installation of refractory castables depend not only on flow , but also on how soon the flow is lost because of setting. The loss of flow (flow decay) has always been one of the main problems of refractory castable manufacturers , a problem that has not been too well described in literature . The flow decay has been studied for a castable system based on alumina , pointing out some general trends . The flow decay was found very temperature sensitive, being strongly accelerated by temperature increases. To compensate for excessive flow loss, a retarder like citric acid may be used. Thus flow decay was measured as a function of citric acid ( retarder) addition at 35℃.展开更多
In order to improve the properties of purging plugs and to prolong their service life,this work attempted to impregnate alumina-spinel castables for purging plugs in refining ladle with saturated magnesium chloride so...In order to improve the properties of purging plugs and to prolong their service life,this work attempted to impregnate alumina-spinel castables for purging plugs in refining ladle with saturated magnesium chloride solution under vacuum.After being impregnated for the first time,the specimens were treated in two different ways:(1)dried at 110℃for 24 h;(2)heated at 600℃for 3 h.Then they were impregnated for the second time.All specimens were heated at 1550℃for 3 h,then the cold properties and the high temperature properties were tested according to corresponding standards.Test results were compared and analyzed.The results show that:after being impregnated,the specimen have both better cold properties and high temperature properties,the microstructure analysis result proves that it is attributed to in situ formed spinel.However,because MgO produced by MgCl2-6H20 decomposing above 527℃can hydrate and destroy specimen microstructure,which can make the properties of specimens impregnated in the second way get worse.By comprehensive consideration,the first scheme way is more suitable.展开更多
Calcium aluminate cement bonded corundum castable specimens were prepared using brown fused corundum （8 - 5, 5 - 3, 3 - 1 mm ） , white fused corundum （ ≤ 1, ≤0. 045 mm）, micro-sized α-Al2O3 and microsilica as s...Calcium aluminate cement bonded corundum castable specimens were prepared using brown fused corundum （8 - 5, 5 - 3, 3 - 1 mm ） , white fused corundum （ ≤ 1, ≤0. 045 mm）, micro-sized α-Al2O3 and microsilica as starting materials. This work focused on investigating the relationship between the bond change in the castable matrix and the strength of the castable with 5 mass% microsilica or without microsilica after heat treatment at 110, 800 and 1 000 ℃, respectively. Chemical bond changes between the microsilica and hy- drates of calcium aluminate cement after drying at 110 ℃ or firing at 800 ℃ were investigated by XPS and FTIR. The results show that Si-O-Al bonds form be- tween the microsilica and hydrates of calcium aluminate cement after drying at 110 ℃ or firing at 800 ℃. Therefore, the increased strength of castable specimens is attributed to the formation of Si-O-Al bonds from 110 ℃ to 800 ℃.展开更多
Effects of three anti-explosion agents：fiber,azo amide,and metal aluminum powder,on the anti-explosion property of Al2O3-SiC-C low-cement castables were researched. The mechanism of the anti-explosion agents was stud...Effects of three anti-explosion agents：fiber,azo amide,and metal aluminum powder,on the anti-explosion property of Al2O3-SiC-C low-cement castables were researched. The mechanism of the anti-explosion agents was studied by observing the microstructure of the castables. The results show that all these agents can improve the anti-explosion performance of the low-cement castables. The anti-explosion performance of the castables is the best by composite adding 0.12% fiber,0.05% azo amide,and 0.1% metal aluminum powder. The main anti-explosion mechanism is that these three agents form apparent pores which increase the permeability.展开更多
Alumina magnesia castable crucible specimens were prepared using tabular corundum （ ≤ 5 mm ）, fused magnesia powder （ ≤0. 088 mm ） , fused spinel powder （ ≤0. 044 mm ） , and α-Al2O3. micropowder （d50 ≤0....Alumina magnesia castable crucible specimens were prepared using tabular corundum （ ≤ 5 mm ）, fused magnesia powder （ ≤0. 088 mm ） , fused spinel powder （ ≤0. 044 mm ） , and α-Al2O3. micropowder （d50 ≤0. 7 μm ） as main starting materials, batching, mixing, shaping, and drying. Slag resistance was determined by static crucible method at 1 600℃ for 3 h adopting two ladle slags with different basicities （3. 40 and 1.03 ）. The corrosion and penetration indexes and microstructure characteristics of the specimens after slag resistance test were analyzed to study the corrosion behaviors of the two slags to alumina magnesia castables. The results show that the corrosion of the low basicity slag to alumina magnesia custables is much more serious than that of the high basicity slag for that their reactions with castables form different products;for the low basicity slab,, the multi-phase coexistence of CA6 and compounds of CaO - Al2O3 -SiO2 in the materials together with volume expansion caused by the formation of CA6 intensify the slag corrosion and penetration ; for the high basicity slag, the reaction between slag and castables generates a CA2 dense layer and a large amount of in-situ MA in the interface, reducing the slag corrosion to the materials effectively.展开更多
This work investigates the effect of the pre-firing temperature of andalusite aggregate(5-3 mm)on the conversion of andalusite,the volume stability,the thermal shock resistance and the slag resistance of Al2O3-SiC-C c...This work investigates the effect of the pre-firing temperature of andalusite aggregate(5-3 mm)on the conversion of andalusite,the volume stability,the thermal shock resistance and the slag resistance of Al2O3-SiC-C castables.The results show that the volume stability and the thermal shock resistance of the castables could be adjusted at different pre-firing temperatures of andalusite aggregates.There was no noticeable difference in the slag resistance between the specimens without andalusite and those with andalusite aggregate pre-fired at different temperatures.展开更多
文摘Low cement (LC) and ultra low cement (ULC) bauxite SiC castables are important and high performance monolithic refractories and they have been widely used in iron making and incinerator linings. In this work, rheological behavior of LC and ULC bauxite based SiC containing castables has been studied, including the effects of SiC content and cement content on rheological properties of the castables. The results show that with an increase of SiC and cement content, rheological properties of the castables deteriorate. On the other hand, moderate amounts of SiC (4%～8%) and of calcium aluminate cement (2%～4%) have very slight influence on rheological properties, (i.e. when the castables are sheared their torque and yield torque only slightly increase with the shearing speed). The rheological characteristics of the castables follow Bingham fluid and always show shear thinning behavior.
基金National Natural Science Foundation of China(52472303 and 52304356).
文摘High-performance alumina-magnesia castables were developed with the addition of nano-CacO_(3) and nano-hydromagnesite.To further understand their dynamic failure mechanism,the quantitative investigation via the employment of the Split-Hopkinson pressure bar(SHPB)method was adopted to test the dynamic failure behavior of alumina-magnesia castables under various impact velocities.The results demonstrate that the greater the impact velocity,the more intense the sample damage.The dynamic compressive stress,the ultimate strain,and the strain energy of all samples display a strain rate hardening effect,and this phenomenon is more conspicuous in the samples incorporating nano-additives.The nano-additives show a positive influence on the dynamic mechanical properties of the castables.
文摘In order to improve the service performance of Al_(2)O_(3)-SiC-C castables,a novel Si-N-O composite micropowder was synthesized by the chemical combustion method.Using brown corundum,sintered alumina,silicon carbide,activeα-Al_(2)O_(3)micropowder,SiO_(2)micropowder,calcium aluminate cement,Si powder and spherical asphalt as the raw materials,adding additive of Si-N-O composite micropowder,Al_(2)O_(3)-SiC-Si_(3)N_(4)/Si_(2)N_(2)O-C castables were prepared.The effects of the Si-N-O composite micropowder addition on the mechanical properties and oxidation resistance of the castables were investigated,and the intrinsic mechanism of strengthening and antioxidation caused by this novel additive was discussed.Experimental results show the introduction of Si-N-O composite micropowder leads to significant improvement in the cold strength,oxidation resistance,thermal shock resistance and hot modulus of rupture of the Al_(2)O_(3)-SiC-C castables.When the Si-N-O composite micropowder addition is approximately 3 mass%,the castable possesses the best comprehensive performance.
基金Key Project of the National Natural Science Foundation of China(Grant No.U21A2058)China Postdoctoral Science Foundation(2023M740971)State Key Laboratory of Refractories and Metallurgy(Wuhan University of Science and Technology,G202209).
文摘The penetration of ladle slag into refractory linings is an essential process in service,and the mechanical properties of the refractory castables are affected by the location and content of slag in the refractory castables.In this work,ladle slag was added into Al_(2)O_(3)-Mgo refractory castables and its influence on the microstructure evolution,mechanical properties and thermal shock resistance of the castables was investigated.The phase composition and contents of the castables during the corrosion process were calculated by FactSage TM(6.2)and studied.The results indicate that the residual strength decreases as the ladle slag addition increases from 0 to 6 mass%.While the hot modulus of rupture of the castable with 6%ladle slag significantly decreases by approximately 80%compared with the one without ladle slag.The elastic modulus and CMOR of the castables decrease with slag-adding,which leads to the increase of liquid phase contents inside the samples.
文摘In order to prolong the working time of calcined flint clay-bauxite castables during construction at high temperature,boric acid was added into the castables. The effect of boric acid on working time and curing cold crushing strength of the castables at 25 ℃ and 35 ℃ were investigated. After 24 h curing in mould and another 24 h curing at 110 ℃ after demoulding,the specimens were heat treated at 1 000 ℃,1 300 ℃,and 1 500 ℃ for 3 h,respectively. The permanent linear change,bulk density,modulus of rupture,and cold crushing strength were determined. The result shows that there is no need to add boric acid when calcined flint clay-bauxite castables works at 25 ℃; when calcined flint clay-bauxite castables works at 35 ℃,boric acid can increase the working time of the castables,but decrease the curing cold crushing strength a little. Adding boric acid into calcined flint clay-bauxite castables doesn＇t worsen performance of the castables.
文摘Thermal behavior and physical properties of castables during curing and drying-out are associated with their binding system. In this work, five alumina based （ Al2O3 〉 87% ） castables with different combinations of binding materials, i. e. , （ 1 ） CA cement （CA） ＋ Reactive alumina （ RA ） ＋ H2O ; （ 2 ） high level addi- tion of CA ＋ Microsilica （MS） ＋ H2O ; （ 3 ） low level addition of CA ＋ MS ＋ H2O ; （4） MS ＋ Hydratable alumina ＋ H20 and （ 5 ） MS ＋ Magnesia ＋ H2O, respectively, have been investigated on the flowability and thermal behavior during curing at room temperature, drying at 110% and heating from 200℃ to 1000℃ at an interval of 100℃ , in terms of water addition, vibration flow value, porosity, dehydration, explosion resistance, cold and hot bending strengths. Differences in dehydrating behavior and the mentioned properties have been revealed and correlated to the binding system.
文摘Microsilica-gel bonded bauxite based no-cement refractory castables（NCCs）have been produced using two readily available dispersants.These NCCs were compared to NCC with Siox X-Zero,a purposely-developed product for microsilica-gel bonded no-cement castable systems to control flow properties and setting characteristics.Three mixing and curing temperatures were applied：5℃,20℃and 35℃.The results show that setting-behaviour and mechanical properties strongly vary with the type of dispersant and the curing temperature.However,both setting and strength are less temperature dependent in the castables with Siox X-Zero.Furthermore,the drying and firing of microsilica-gel bonded NCCs were investigated.Since microsilica-gel bond system contains only a small amount of bound water,the castables can be fired at very high heating rates,once the free water has been removed.
文摘The castables specimens were prepared using white fused alumina particle and powder, α-Al2O3 micropowder, hydrated alumina, nano calcium carbonate or calcium aluminate cement as starting materials. Effects of nano calcium carbonate addition on phase compositions, strength and microstructure of corundum based castables were studied. The calcium aluminate cement-containing corundum based castables with the same CaO amount was also tested for comparison. The results show that, when temperature is higher than 900 ℃ , the phase compositions of nano CaCO3-containing mixture and the calcium aluminate cement containing mixture are the same, but the forming mechanism, modality and distribution of new phases in the castables are different. With temperature rising, the hydration cement dehydrates and reacts inside cement forming calcium aluminate until the alumina in cement is not enough for the reaction （ternperature is 91 400 ℃ ） , then reacts with the surrounding alumina forming cluster CA6 in the castables. The change process of nano CaCO3 in corundum based enstables is that nano calcium carbonate decomposes to CaO after firing at 800℃ which reacts with Al2O3 forming amorphous calcium aluminate that causes an in-situ bonding. With temperature rising, the formed calcium aluminate reacts with Al2O3 in matrix and wholly forms tabular CA6 at 1 600 ℃ , which distributes uniformly in the castables. The cold and hot strength of the castables with nano calcium carbonate are obviously higher than those of the castables without nano calcium carbonate, especially at 800 -1 000 ℃ due to smaller size and higher dispersion of the nano calcium carbonate and its different reaction mechanism with Al2O3.
文摘A series of corundum based castables with 0,2%,4%,6%,and 8% α-Al2O3 micropowders were prepared using tabular alumina aggregates （6-3,3-1 and ≤1 mm） and fines （≤0.088 and ≤0.045 mm）,calcium aluminate cement,and α-Al2O3 micropowders （d50=1.754 μm） as starting materials. Cold mechanical strength and pore size distribution of the castables specimens after heat treatment at 110,1 100 and 1 500 ℃ were tested,respectively. The quantitative relationship between strength and apparent porosity,and that between strength and median pore diameter were verified by Atzeni equation. The correlation between interval of pore size and mechanical strength of specimens was also studied by means of gray relational theory. The results show that：（1） the pore size distribution of castables is strongly influenced by both micropowders filling and matrix sintering; the addition of micropowders decreases median pore diameter while the sintering process increases it; （2） when adding a constant correction term,Atzeni equation can substantially describe the quantitative relationship between median pore diameter and strength of castables specimens after heat treatment at the same temperature; the significant differences of the gray relational degree between the interval of pore size and castables strength are characterized; it is also found that for the same interval of pore size,the gray relational degree isaffected by the heat treatment temperature; the pore size interval 〈0.5 μm has the highest gray relational degree with the strength at 110-1 500 ℃.
文摘In this study, the properties of self-flowing ultra-low cement castables in Al2O3-SiC-C system have been investigated and compared to vibration castables. The major physical and mechanical properties, microstructure and corrosion behavior of these castables against slag have been evaluated. The results showed that the microstructure of Al2O3-SiC-C self-flowing castable is more uniform than the vibrated structure. Also self-flowing castable has smaller pore size and more uniform pore size distribution. Hence, density, strength, oxidation and slag resistance of the self-flowing castables is higher than that of vibration castables. Therefore, besides other benefits such as noise free, easy installation, fewer mold defects and reduced installation costs, Al2O3-SiC-C self flowing ultra low cement castables will have longer service life in comparison with vibration casables.
文摘The properties and microstructure of sol self-clean bonded Al2O3-SiC-C castable in iron runner were studied, and the relation between the amount of sol self- clean binder and the properties of castable were discussed. It is believed that the addition of sol self-clean binder can improve the compressive strength, but has little effect on the bulk density and the apparent porosity, which enable the castable to be applicable in different conditions.
文摘CMA72 bonded Al2 O3 - MgO castable is promising for application of steel ladle wall, because of unique combination of thermo-mechanical properties, slag corro- sion resistance and cost benefit. In these castables, mi- crosilica can be introduced to counterbalance the expan- sion generated by spinel formation. In this paper, the of microsilica dosage on properties of eastables was evaluated. Expansion, expressed by the permanent linear change （PLC）, is highly dependent on the dosage of microsilica. Unexpected expansion occurs when the dos- age of microsilica is too low due to dominant effect of spinel and CA6 formation. Too high dosage results in sintering shrinkage, which is related to amount of liquid phase generated by microsilica addition. In addition, HMOR declines dramatically with increasing microsilica dosage. Considering the balance between expansion con- trol and hot property retention, 1.0 mass% of microsili- ca is recommended for the castable containing 4 mass% of magnesia.
文摘Magnesite fine powder, natural silica powder,light-burned magnesia fine powder, silica fume and middle grade magnesia fine powder were used as the starting materials,and silica sol as binder to get high purity lightweight spherical forsterite aggregates. The mixture was granulated on a disc pelletizer and then calcined at 1 400 ℃ for 3h. The synthesized spherical forsterite aggregates were added in Mg O based castables with MgO-SiO2-H2O binding system to replace equaldensity high purity common forsterite aggregates. Effect of spherical forsterite aggregates addition on properties of MgO based castables was investigated. The results show that: compared with common aggregates,lightweight spherical forsterite aggregates can improve castables ’flow ability and decrease water addition; addition of spherical aggregates has little effect on cold strength of castables; with the increase of spherical aggregate addition,shrinkage of specimens after drying and heating at intermediate temperatures decreases,but the expansion of specimens after heating at high temperatures increases,bulk density decreases and apparent porosity increases,and thermal conductivity declines.
基金financial support from the National Natural Science Foundation of China ( Grant No.51402089)the Plan of Young-backbone Teachers of Colleges and Universities in Henan Province ( Project No.2015GGJS-045)
文摘Compared with traditional aggregates,spherical aggregates with high flowability,easy control of particle size distribution and favor of dense packing and so on,are expected to replace traditional aggregates as important raw materials for future high performance refractories. Therefore,investigation of effects of spherical aggregates addition on properties of refractories becomes very meaningful. Using A70 mullite traditional aggregates and A70 mullite spherical aggregates, bauxite homogenization powder,microsilica,and calcium aluminate cement as raw materials,different AlO-SiOsystem low cement castables were prepared by replacing conventional aggregates with spherical aggregates. The effect of spherical aggregates addition on workability and mechanical properties of castables after heated at different temperatures was researched,and microstructure of the specimen was analyzed by SEM. Compared with traditional irregularly shaped aggregates,spherical aggregates endow castables with better flowability and easy pump ability. By introduction of spherical aggregates into the castables,flowability and pumpability are significantly improved,and water addition and ball completely sunk time are reduced. The introduction of spherical aggregates is favorable to density and cold crushing strength of castables,but unfavorable to CMOR. The effect of spherical aggregates addition on HMOR at1 400 ℃ can be negligible. Microstructure analysis showsthat the boundary bonding between spherical aggregates and matrix is strong,similar to the traditional aggregates.
文摘Installation of refractory castables depend not only on flow , but also on how soon the flow is lost because of setting. The loss of flow (flow decay) has always been one of the main problems of refractory castable manufacturers , a problem that has not been too well described in literature . The flow decay has been studied for a castable system based on alumina , pointing out some general trends . The flow decay was found very temperature sensitive, being strongly accelerated by temperature increases. To compensate for excessive flow loss, a retarder like citric acid may be used. Thus flow decay was measured as a function of citric acid ( retarder) addition at 35℃.
文摘In order to improve the properties of purging plugs and to prolong their service life,this work attempted to impregnate alumina-spinel castables for purging plugs in refining ladle with saturated magnesium chloride solution under vacuum.After being impregnated for the first time,the specimens were treated in two different ways:(1)dried at 110℃for 24 h;(2)heated at 600℃for 3 h.Then they were impregnated for the second time.All specimens were heated at 1550℃for 3 h,then the cold properties and the high temperature properties were tested according to corresponding standards.Test results were compared and analyzed.The results show that:after being impregnated,the specimen have both better cold properties and high temperature properties,the microstructure analysis result proves that it is attributed to in situ formed spinel.However,because MgO produced by MgCl2-6H20 decomposing above 527℃can hydrate and destroy specimen microstructure,which can make the properties of specimens impregnated in the second way get worse.By comprehensive consideration,the first scheme way is more suitable.
文摘Calcium aluminate cement bonded corundum castable specimens were prepared using brown fused corundum （8 - 5, 5 - 3, 3 - 1 mm ） , white fused corundum （ ≤ 1, ≤0. 045 mm）, micro-sized α-Al2O3 and microsilica as starting materials. This work focused on investigating the relationship between the bond change in the castable matrix and the strength of the castable with 5 mass% microsilica or without microsilica after heat treatment at 110, 800 and 1 000 ℃, respectively. Chemical bond changes between the microsilica and hy- drates of calcium aluminate cement after drying at 110 ℃ or firing at 800 ℃ were investigated by XPS and FTIR. The results show that Si-O-Al bonds form be- tween the microsilica and hydrates of calcium aluminate cement after drying at 110 ℃ or firing at 800 ℃. Therefore, the increased strength of castable specimens is attributed to the formation of Si-O-Al bonds from 110 ℃ to 800 ℃.
文摘Effects of three anti-explosion agents：fiber,azo amide,and metal aluminum powder,on the anti-explosion property of Al2O3-SiC-C low-cement castables were researched. The mechanism of the anti-explosion agents was studied by observing the microstructure of the castables. The results show that all these agents can improve the anti-explosion performance of the low-cement castables. The anti-explosion performance of the castables is the best by composite adding 0.12% fiber,0.05% azo amide,and 0.1% metal aluminum powder. The main anti-explosion mechanism is that these three agents form apparent pores which increase the permeability.
文摘Alumina magnesia castable crucible specimens were prepared using tabular corundum （ ≤ 5 mm ）, fused magnesia powder （ ≤0. 088 mm ） , fused spinel powder （ ≤0. 044 mm ） , and α-Al2O3. micropowder （d50 ≤0. 7 μm ） as main starting materials, batching, mixing, shaping, and drying. Slag resistance was determined by static crucible method at 1 600℃ for 3 h adopting two ladle slags with different basicities （3. 40 and 1.03 ）. The corrosion and penetration indexes and microstructure characteristics of the specimens after slag resistance test were analyzed to study the corrosion behaviors of the two slags to alumina magnesia castables. The results show that the corrosion of the low basicity slag to alumina magnesia custables is much more serious than that of the high basicity slag for that their reactions with castables form different products;for the low basicity slab,, the multi-phase coexistence of CA6 and compounds of CaO - Al2O3 -SiO2 in the materials together with volume expansion caused by the formation of CA6 intensify the slag corrosion and penetration ; for the high basicity slag, the reaction between slag and castables generates a CA2 dense layer and a large amount of in-situ MA in the interface, reducing the slag corrosion to the materials effectively.
基金the National Natural Science Foundation of China (51572244 and U1604252, 51672255) for the financial supportpartly co-financed by Imerys Aluminates
文摘This work investigates the effect of the pre-firing temperature of andalusite aggregate(5-3 mm)on the conversion of andalusite,the volume stability,the thermal shock resistance and the slag resistance of Al2O3-SiC-C castables.The results show that the volume stability and the thermal shock resistance of the castables could be adjusted at different pre-firing temperatures of andalusite aggregates.There was no noticeable difference in the slag resistance between the specimens without andalusite and those with andalusite aggregate pre-fired at different temperatures.
