钢铁研究学报(英文版)
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2022 Vol. 29 No. 7
Published: 2022-07-25
1041
Ji-yuan Luo, Xin-ming Ren, Xiao-chuan Chong, Dong-hai Ding, Bei-yue Ma, Guo-qing Xiao, Jing-kun Yu
Recent progress in synthesis of composite powders and their applications in low-carbon refractories
The development of low-carbon refractories is of great significance, but it is limited by the deteriorated properties that resulted from the decreased graphite content. Incorporating composite powders has proved to be effective in improving the properties of low-carbon refractories. The recent progress in the synthesis of composite powders including modified graphite, nanocarbon-containing composite powders, oxide/non-oxide and non-oxide composite powders and their applications in low-carbon refractories were reviewed, and the future development of composite powder technology was prospected.
2022 Vol. 29 (7): 1041-1051 [
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1052
Chao Yu, Bo Dong, Yu-feng Chen, Bei-yue Ma, Jun Ding, Cheng-ji Deng, Hong-xi Zhu, Jing-hui Di
Enhanced oxidation resistance of low-carbon MgO–C refractories with ternary carbides: a review
The demand for low-carbon MgO–C refractories is ever growing to meet the development of advanced steelmaking technologies and efficient energy conservation. Meanwhile, to improve the oxidation resistance and inhibit the weakness of low-carbon MgO–C refractories, antioxidants are necessary. The application of ternary carbides that focused on improving the oxidation performance of MgO–C refractories has been explored, and the ternary carbides including Al
4
O
4
C, Al
8
B
4
C
7
, Al
4
SiC
4
, Ti
2
AlC, Ti
3
AlC
2
, and Ti
3
SiC
2
have been proved effective. The crystal structure, physical properties, oxidation behavior, and synthesis of these ternary carbides were summarized, and their oxidation mechanism in assisting antioxidation of MgO–C refractories was discussed. In addition, the potential aspects related to the usage and development of ternary carbides in low-carbon MgO–C refractories were proposed.
2022 Vol. 29 (7): 1052-1062 [
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1063
Qian Sun, En-hui Wang, Xin-mei Hou, Zhi-jun He, Tong-xiang Liang
Effect and mechanism of nano-Ca
10
(PO
4
)
6
(OH)
2
additive on compressive strength of calcium aluminate cement at high temperature
Calcium aluminate cement (CAC) is widely used as a binder for refractory materials, and thus the improvement in compressive strength is of vital importance for CAC applied at high temperature. For this purpose, nano-Ca
10
(PO
4
)
6
(OH)
2
additive with a ratio of 0.5–1.5 mass% was added with the water-cement ratio to be 0.4. X-ray diffraction and isothermal calorimetry analysis demonstrate that nano-Ca
10
(PO
4
)
6
(OH)
2
additive can shorten the hydration process and promote the formation of main hydrates of CaAl
2
O
4
·10H
2
O (CAH
10
) and Ca
2
Al
2
O
5
·8H
2
O (C
2
AH
8
). In addition, scanning electron microscopy results suggest that nano-Ca
10
(PO
4
)
6
(OH)
2
can protect CAH
10
and C
2
AH
8
from being destroyed during the calcination, guaranteeing that these thin lamellar crystals are intertwined to form the denser microstructure. Benefited from above effects, nano-Ca
10
(PO
4
)
6
(OH)
2
can obviously improve the compressive strength of the CAC mortar samples cured for 7 d after calcination at 1100 °C, while the improving effect is dependent upon its contents. Especially, compared with the one without the additive, the compressive strength of the sample with 1.0% nano-Ca
10
(PO
4
)
6
(OH)
2
is increased by 14%.
2022 Vol. 29 (7): 1063-1072 [
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1073
Rui-qiang Bai, Si-yang Liu, Fei-xiong Mao, Yuan-yuan Zhang, Xin Yang, Zhi-jun He
Wetting and corrosion behavior between magnesia–carbon refractory and converter slags with different MgO contents
The influence of MgO content in slag on wetting and corrosion behavior between slag and MgO–C refractory was investigated. It can be known from the high-temperature wetting experiment that as the MgO content in the slag increases, the final contact angle between the slag and the MgO–C refractory gradually increases and the penetration depth of the slag into the refractory gradually decreases from 60.54 μm (when the MgO content is 8%) to 28.11 μm (when the MgO content is 12%). The CaO and SiO
2
in the slag penetrate into the MgO–C refractory along the pores or surface cracks formed by carbon oxidation and react with MgO to generate a large amount of low-melting compound CaO–MgO–SiO
2
, which accelerates the corrosion of the refractory. As the MgO content in slag increases, the viscosity of the slag increases and the fluidity becomes worse, so that the mass transfer and diffusion of molecules or ions in the slag are weakened. In addition, the increase in MgO reduces the activity of FeO in the slag, which inhibits the interfacial chemical reaction, thereby weakening the wetting effect caused by the reaction.
2022 Vol. 29 (7): 1073-1079 [
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1080
Bei-yue Ma, Xin-ming Ren, Zhi Gao, Fan Qian, Zhao-yang Liu, Guo-qi Liu, Jing-kun Yu, Gao-feng Fu
Influence of pre-synthesized Al
2
O
3
–SiC composite powder from clay on properties of low-carbon MgO–C refractories
To improve the properties of low-carbonization of MgO–C refractories, the introduction of composite additives is an effective strategy. Al
2
O
3
–SiC composite powder was prepared from clay using electromagnetic induction heating and carbon embedded methods. Further, the Al
2
O
3
–SiC composite powder synthesized by electromagnetic induction heating at 600 A was added into low-carbon MgO–C refractories (4 wt.%) to improve their properties. The results showed that when the addition amount of Al
2
O
3
–SiC composite powder is within the range of 2.5–5.0 wt.%, the properties of low-carbon MgO–C samples were significantly improved, e.g., the apparent porosity of 7.58%–8.04%, the bulk density of 2.98–2.99 g cm
-3
, the cold compressive strength of 55.72–57.93 MPa, the residual strength after three air quenching at 1100 °C of 74.86%–78.04%, and the decarburized layer depth after oxidized at 1400 °C for 2 h of 14.03–14.87 mm. Consequently, the idea for the rapid synthesis of Al
2
O
3
–SiC composite powder provides an alternative low-carbon MgO–C refractories performance optimization strategy.
2022 Vol. 29 (7): 1080-1088 [
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1089
Mao-qi Ju, Man-fei Cai, Yong-he Liang, Jian-hua Nie, Meng-zhen Guo
Application of calcium alumino-titanate to taphole clay
Calcium alumino-titanate (CAT) can be used as a raw material owing to its excellent refractoriness and thermal expansion. CAT-containing taphole clay (THC) with different particle sizes was prepared and characterized. The results indicated that THC with CAT aggregate has better thermo-mechanical performance than that with a fine CAT powder because of different sintering processes. The CAT aggregate and SiO
2
reacted and formed liquid phase covering their surface, enhancing the bonding of the particle–matrix and promoting the internal transformation of the substance. Further, the mullite was formed in aggregate with the interwoven network structure. Fine CAT powder has a higher specific surface area, and its surface energy decreases with the particle size. This could cause a reaction between CAT and SiO
2
at relatively low temperature, making it unable to form a core–shell structure similar to that of the aggregate, with the excessive liquid phase affecting the performance of the samples. Meanwhile, the liquid phase was formed to close the pores and cover the SiC surface, and this was found to enhance the oxidation resistance. A corrosion test confirmed that the THC refractories with CAT aggregates showed better corrosion resistance than other samples. Scanning electron microscopy and energy-dispersive spectrometry results indicated that Ti(C,N) transformed by TiO
2
in CAT was deposited at the interface between the molten slag and the refractory, and it efficiently prevented the penetration and reaction owing to its high melting point and small wetting angle with the slag.
2022 Vol. 29 (7): 1089-1100 [
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1101
Fan Qian, Hua-long Li, Wen-gang Yang, Hai-rong Guo, Guo-qi Liu, Hong-xia Li, Bei-yue Ma
Corrosion resistance of BN–ZrO
2
ceramics with different additives by molten steel
BN–ZrO
2
ceramics with different additives such as SiC, Al
2
O
3
and MgAl
2
O
4
were fabricated by hot pressing sintering process to study sintering properties and corrosion resistance by the rotary immersion molten steel test. The results showed that SiC, Al
2
O
3
and MgAl
2
O
4
can improve the sintering properties of BN–ZrO
2
ceramics; especially, the introduction of SiC can significantly improve the hardness of the material; thus, the above compounds will help to improve the wear resistance of BN–ZrO
2
ceramics. The exposed oxide layer is in contact with molten steel and forms liquid phase after BN oxidation and B
2
O
3
volatilization, additives can significantly affect the properties of liquid phase, and m-ZrO
2
grains are sintered and grown by dissolution–precipitation mechanism by liquid phase. Consequently, Al
2
O
3
and MgAl
2
O
4
are more conducive to the formation of working layer with solid skeleton, which determines the corrosion resistance of BN–ZrO
2
ceramics.
2022 Vol. 29 (7): 1101-1109 [
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1110
Yan-zhu Huo, Hua-zhi Gu, Juan Yang, Ao Huang, Zheng Ma
Thickness monitoring and discontinuous degradation mechanism of wear lining refractories for refining ladle
As a functional metallurgical container for molten steel, refining ladle has a great influence on the smelting safety and quality of steel. The online monitoring of the residual thickness for ladle lining was applied to increase the smelting efficiency and safety. It is found that the ladle refractories show obvious discontinuous degradation characteristics through the monitoring data. Moreover, the degradation of low-carbon magnesia–carbon brick at slag line and corundum-based castable at steel bath was calculated according to the established corrosion model and crack propagation model, respectively. The discontinuous degradation mechanism of the ladle refractories is illustrated, which is of great significance to the optimal configuration of the ladle lining refractories.
2022 Vol. 29 (7): 1110-1118 [
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1119
Fang-guan Tan, Sheng-li Jin, Zhu He, Xiong Liang, Ya-wei Li, Jing Li
Numerical study of creep effect on purging plug performance under cyclic service
The service life of the purging plug is one of the fundamental factors that determine the downtime and usage efficiency of the whole ladle. The creep behaviour of the purging plug was thus investigated to identify the possible failure mechanism. At first, the creep parameters of the Norton–Bailey strain hardening rule were inversely identified via the results of the creep test. Then, the thermal-solid coupling model approach was employed to predict the creep behaviour of the purging plug, in which the Norton–Bailey strain hardening rule was applied. The numerical results show that the temperature of the purging plug presents a cyclic trend after the first service period since the preheating temperature is lower than the temperature of molten steel. Furthermore, the distribution of the creep strain intensity in a layered form could also contribute to a gradual spalling of the purging plug end in service. Besides, the creep strain concentration around the slit can be responsible for the clogging of the purging plug.
2022 Vol. 29 (7): 1119-1128 [
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1129
Zi-xu Ji, Wen-jing Liu, Ning Liao, Ya-wei Li, Tian-bin Zhu
Influence of
h
-BN particle size on fracture behavior and thermal shock resistance of Al
2
O
3
–C refractories
h
-BN can be applied in Al
2
O
3
–C refractories to substitute graphite due to their similar crystal structure and better resistance to molten steel and oxidation. The effects of
h
-BN particle size on the mechanical properties and fracture behavior of Al
2
O
3
–C refractories were investigated through wedge splitting test and microstructural analyses. The obtained results demonstrated that the addition of larger-sized
h
-BN was conducive to the growth of in situ formed SiC whiskers, which contributed to the highest flexural strength (42.63 ± 3.10 MPa) of specimen D10. In comparison, the smaller-sized
h
-BN can induce more crack propagation paths along the interface and within matrix, leading to more tortuous crack propagation paths, and thus the thermal shock-related parameters such as specific fracture energy, characteristic length, and thermal shock resistance were improved. Consequently, the residual strength ratio of Al
2
O
3
–C refractories was increased from 35.5% to 42.5% with decreasing the
h
-BN particle size from 10 to 0.1 μm.
2022 Vol. 29 (7): 1129-1137 [
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1138
Yi-ming She, Jie-fu Lang, Di An, Chao-wei Si, Xu-dong Luo, Zhi-peng Xie, Jie-gang You
Sintering kinetics involving grain growth and densification of Mg-PSZ nanopowders
Sintering kinetics have been found to be effective in judging the evolution of ceramics. By using magnesium oxide-partially stabilized zirconia (Mg-PSZ) powder prepared by co-precipitation as raw materials, the evolution of densification and grain growth for Mg-PSZ ceramics were investigated. The results indicated that the densification of samples was mainly controlled by grain boundary diffusion in intermediate sintering stage. During the sintering process, the grain growth mechanisms included normal grain growth, abnormal grain growth and solid solution drag-controlled grain growth. Interestingly, the apparent activation energy for grain growth of Mg-PSZ ceramics is lower than that of ZrO
2
–Y
2
O
3
ceramics in the solid solution drag-controlled grain grow process, which will cause grain to grow easily. The sintering kinetics and microstructure of Mg-PSZ ceramics were studied, and the kinetic equation of grain growth at different temperatures was established. The results show that the strength difference between Mg-PSZ and yttrium oxide-stabilized zirconia is closely related to the easy grain growth of Mg-PSZ ceramics.
2022 Vol. 29 (7): 1138-1144 [
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1145
Zhong-feng Xia, Chang-hao Chen, Wen-hao Chi, Zhou-fu Wang, Hao Liu, Yan Ma, Xi-tang Wang
Rheological and mechanical properties of aluminosilicious cementitious materials as refractory castable binders
Metakaolin (MK) is an important refractory raw material, which has been used as a cementitious material. In order to improve the bonding strength of MK, the composite cementitious materials were prepared by MK mixed with hydrat- able alumina (HA) and microsilica (MS), respectively. The silane coupling agent (SCA) was introduced as a modifying agent. The rheological properties of MK-based composite cementitious slurries were investigated. The mechanical properties of corundum castables bonded with the composite cementitious materials and calcium aluminate cement (CAC) were comparatively studied. The results show that SCA improves the rheological properties of MK-based composite cementitious materials. The slurry of MK–MS mixture flows in a plastic manner, while the slurry of MK–HA mixture presents pseudoplastic flow. The addition of SCA reduces the yield stress value of the MK–HA slurry. The bonding strength of castables bonded with MK-based composite cementitious materials is lower than that of CAC bonding castables. The room temperature strength of MK–MS composite bonding castable remains the highest after being treated either at 1100 or 1550 °C, and its high temperature modulus of rupture is higher than that of CAC bonding castables with microsilica added.
2022 Vol. 29 (7): 1145-1151 [
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