Method for evaluating pore structure of refractory material by using industrial CT (Computed Tomography)

Abstract

The invention relates to the technical field of material analysis, in particular to a method for evaluating a pore structure of a refractory material by using industrial CT, which comprises the following steps: selecting an X-ray source parameter, a detector parameter, a focal length and the like of the industrial CT to be matched with a refractory material with different thicknesses, selecting a filter to avoid image noise, identifying an internal structure of the refractory material, and evaluating the pore structure of the refractory material. And obtaining a two-dimensional projection image of the internal structure. According to the method, the image noise is reduced through the filtering technology, the internal structure of the refractory material can be identified more accurately, the data integrity is ensured, a more accurate three-dimensional model can be generated, the analysis of the pore structure is more detailed and accurate, and by quantitatively analyzing the pore size, shape and distribution of the refractory material, the analysis accuracy of the refractory material is improved. The performance change of the material can be effectively monitored, the prediction capability of the refractory material in practical application is improved, and the application safety and reliability of the refractory material in an extreme environment are enhanced.

Description

Technical Field

[0001] The present invention relates to the technical field of material analysis, and particularly to a method for evaluating the pore structure of refractory materials using industrial CT. Background Art

[0002] The technical field of material analysis mainly studies the composition and structure of materials, and how factors affect the properties and functions of materials. This field involves a variety of sciences and engineering technologies, including chemical analysis, physical testing, mechanical property testing, and microstructural analysis, etc. Among them, microstructural analysis is used to explore the internal microstructure of materials, such as crystal structure, pore distribution, and cracks, etc., which is crucial for developing new materials or improving the performance of existing materials. The application of material analysis is extensive, covering from basic research to various industrial applications. For example, in the aerospace, construction, electronics, and automotive industries, it is used to optimize the use of materials and improve the reliability and efficiency of products.

[0003] Among them, the method for evaluating the pore structure of refractory materials using industrial CT refers to evaluating the size, distribution, and connectivity of pores in refractory materials through industrial computed tomography technology. This method can non-destructively view the internal structure of materials, which is very useful for understanding the heat resistance, mechanical strength, and life prediction of materials. The application of this technology enables designers and engineers to more accurately simulate and predict the performance of materials in high-temperature environments, optimize material formulations and processing technologies, and ensure the performance and safety of components under extreme conditions.

[0004] Although the existing technologies cover a variety of testing and analysis methods in material analysis, in practical applications, there are limitations in the resolution and accuracy of the evaluation of the internal microstructure of refractory materials. Traditional methods such as physical sectioning or basic imaging technologies cannot non-destructively view the internal structure and are limited by the thickness and complexity of the materials. These limitations lead to inaccurate prediction of material performance in high-temperature environments, which can cause mistakes in material design and application. For example, inaccurate evaluation of the pore structure of refractory materials can lead to incorrect estimation of the heat resistance and mechanical strength of materials, affecting the stability and safety of the entire structure. Summary of the Invention

[0005] In order to solve the technical problems that there are limitations in the resolution and accuracy of the evaluation of the internal microstructure of refractory materials in the existing technology, traditional methods such as physical sectioning or basic imaging technologies cannot non-destructively view the internal structure and are limited by the thickness and complexity of the materials. These limitations lead to inaccurate prediction of material performance in high-temperature environments, which can cause mistakes in material design and application. For example, inaccurate evaluation of the pore structure of refractory materials can lead to incorrect estimation of the heat resistance and mechanical strength of materials, affecting the stability and safety of the entire structure, the embodiments of the present invention provide a method for evaluating the pore structure of refractory materials using industrial CT. The technical solution is as follows:

[0006] On the one hand, a method for evaluating the pore structure of refractory materials using industrial CT is provided. The method includes:

[0007] S1: Select the X-ray source parameters, detector parameters, focal length, etc. of the industrial CT to match refractory materials with different thicknesses. Select a filter to avoid image noise, identify the internal structure of the refractory material, and obtain a two-dimensional projection image of the internal structure.

[0008] S2: Based on the two-dimensional projection image of the internal structure, perform a full-range industrial CT scan on the refractory material. By continuously rotating the refractory material and gradually collecting projection images at multiple angles, verify the integrity of the image data to obtain a full-range projection data set.

[0009] S3: Use the full-range projection data set to reconstruct a two-dimensional image into a three-dimensional model. Use threshold segmentation to extract the pore structure inside the refractory material, verify the matching degree between the model and the real-time physical properties, and construct a three-dimensional structure model.

[0010] S4: Use the three-dimensional structure model to quantitatively analyze the size, shape, and distribution of the pores in the refractory material, identify changes in the pore structure performance of the material, and obtain a pore characteristic analysis result.

[0011] S5: Through the pore characteristic analysis result, conduct a pore quality assessment of the refractory material, including evaluating the uniformity of the pore structure, analyzing the performance and reliability of the refractory material in real-time applications, and obtaining a pore quality assessment result.

[0012] S6: According to the pore quality assessment result, evaluate the stability and durability of the refractory material in a high-temperature environment to obtain an evaluation result of the pore structure performance of the refractory material.

[0013] As a further solution of the present invention, the two-dimensional projection image of the internal structure with gray-scale differences includes the X-ray source parameters of the industrial CT, the type of filter selected, and the optimized settings for the ray penetration ability of the refractory material. The full-range projection data set includes multi-angle X-ray projection images of the refractory material, the resolution and contrast parameters of the images, and a complete image sequence covering multiple parts of the refractory material. The three-dimensional structure model includes the three-dimensional shape of the refractory material, the internal pore structure information, and the position of the pores relative to the periphery of the material. The pore characteristic analysis result includes the size distribution of the pores, the shape classification, and the spatial distribution map in the material. The pore quality assessment result includes the uniformity score of the pore structure, the quality grade, and the comparative analysis with the ideal standard. The evaluation result of the pore structure performance of the refractory material includes the stability rating in a high-temperature environment, the durability test result, and the recommended application fields.

[0014] As a further solution of the present invention, the steps of selecting the X-ray source parameters, detector parameters, focal length, etc. of industrial CT to match refractory materials with different thicknesses, selecting a filter to avoid image noise, and identifying the internal structure of the refractory material to obtain a two-dimensional projection image of the internal structure are specifically as follows:

[0015] S101: Select the X-ray source parameters of industrial CT, adjust the voltage of the X-ray and detector parameters according to the different thicknesses of the refractory material, test the penetration ability of different voltages and detector parameters, and obtain the ray parameter configuration;

[0016] S102: Based on the ray parameter configuration, analyze the influence of the filter material on image noise, compare the effects of different material filters through experiments, select the filter material and thickness with the best noise reduction effect to optimize the image quality, and obtain the filter selection result;

[0017] S103: Adopt the filter selection result, adjust the exposure time and image optimization settings of industrial CT scanning, scan the refractory material, and obtain a two-dimensional projection image of the internal structure.

[0018] As a further solution of the present invention, based on the two-dimensional projection image of the internal structure, perform a full-range industrial CT scan on the refractory material. By continuously rotating the refractory material and gradually collecting projection images from multiple angles, verify the integrity of the image data. The steps to obtain the full-range projection data set are specifically as follows:

[0019] S201: Based on the two-dimensional projection image of the internal structure, install the refractory material on the industrial CT scanning table and perform positioning. Rotate 360° around the center of the refractory material to obtain multi-angle positioning records;

[0020] S202: Adopt the multi-angle positioning records, continuously operate the industrial CT scanning device for ray penetration, gradually collect the projection images of the refractory material, and adjust the image collection frequency, exposure time, and integration time to obtain multi-angle projection data;

[0021] S203: According to the multi-angle projection data, check the projection data, check the integrity and consistency of the image data, verify that the data is complete and normal, and generate a full-range projection data set.

[0022] As a further solution of the present invention, adopt the full-range projection data set, reconstruct the two-dimensional image into a three-dimensional model, use threshold segmentation to extract the pore structure inside the refractory material, verify the matching degree between the model and the real-time physical properties, and the steps to construct a three-dimensional structure model are specifically as follows:

[0023] S301: Based on the omnidirectional projection dataset, use computer image processing technology to reconstruct a two-dimensional image into a three-dimensional model, set reconstruction parameters (such as median filtering, etc.) to optimize the accuracy of the model, and obtain a record of the reconstruction parameter settings.

[0024] S302: According to the record of the reconstruction parameter settings, extract the pore structure inside the refractory material, adjust the image threshold to verify the representation and size consistency of the pores, and generate a detailed diagram of the pore structure.

[0025] S303: Use the detailed diagram of the pore structure to conduct a comparative analysis of the model and the real-time physical properties, check the matching degree between the model and the entity, and construct a three-dimensional structure model.

[0026] As a further solution of the present invention, the steps of using the three-dimensional structure model to quantitatively analyze the size, shape, and distribution of the pores in the refractory material, identify changes in the pore structure performance of the material, and obtain the pore characteristic analysis results are specifically as follows:

[0027] S401: Based on the three-dimensional structure model, measure the size and shape of the pores in the refractory material, collect multi-dimensional data of the pores in the refractory material, and obtain pore size data.

[0028] S402: According to the pore size data, iteratively analyze the distribution characteristics of the pores in the refractory material, statistically analyze the spatial distribution law and frequency of the pores in the refractory material, analyze the pore distribution in the refractory material, and obtain the pore distribution identification result.

[0029] S403: Through the pore distribution analysis result, combine the data of the size, shape, and distribution of the pores in the refractory material to evaluate and identify changes in the pore structure performance of the refractory material, and obtain the pore characteristic analysis result.

[0030] As a further solution of the present invention, the steps of conducting a pore quality assessment of the refractory material through the pore characteristic analysis result, including evaluating the uniformity of the pore structure, analyzing the performance and reliability of the refractory material in real-time applications, and obtaining the pore quality assessment result are specifically as follows:

[0031] S501: According to the pore characteristic analysis result, collect and calculate the uniformity index of the pore structure, numerically evaluate the regularity and uniformity of the pores, and obtain the pore uniformity assessment result.

[0032] S502: Based on the pore uniformity assessment result, combine the use environment and application conditions of the refractory material, simulate the real-time application scenario, analyze the performance of the refractory material under the expected working conditions, and generate the real-time application performance analysis result.

[0033] S503: Evaluate the overall quality and reliability of the refractory material based on the real-time application performance analysis results. Refer to the performance stability and long-term reliability of the material in real-time applications to obtain the pore quality evaluation results.

[0034] As a further solution of the present invention, the steps of evaluating the stability and durability of the refractory material in a high-temperature environment based on the pore quality evaluation results to obtain the evaluation results of the pore structure performance of the refractory material are specifically as follows:

[0035] S601: Use the pore quality evaluation results to conduct environmental simulation, set high-temperature condition parameters, test the stability and durability of the refractory material in the simulated high-temperature environment, record the reactions and performance changes of the refractory material, and obtain the high-temperature environment test results;

[0036] S602: Based on the high-temperature environment test results, conduct data analysis on the performance attenuation and structural loss of the refractory material, calculate the real-time durability of the refractory material, and obtain the durability adjustment plan;

[0037] S603: Implement the durability adjustment plan, evaluate the capabilities of the refractory material in different industrial environments, verify the optimization of the application and performance of the refractory material, and obtain the evaluation results of the pore structure performance of the refractory material.

[0038] As a further solution of the present invention, the formula for calculating the real-time durability of the refractory material is:

[0039]

[0040] Where is the expected durability of the material, β0 represents the intercept of the regression line, β1, β2, β3, and β4 are the coefficients adjusted for temperature, time, material composition, and material density respectively, T represents the test temperature, t represents the exposure time, C is the percentage of specific chemical components of the material, and B represents the material density.

[0041] The beneficial effects brought by the technical solutions provided in the embodiments of the present invention at least include:

[0042] By performing industrial CT scanning on refractory materials, adjusting the parameters of the X-ray source to better adapt the ray energy to materials of different thicknesses, and reducing image noise through filtering techniques, the internal structure of refractory materials can be identified more accurately. This precise equipment configuration and all-round scanning not only ensure the integrity of data but also generate a more accurate three-dimensional model, enabling a more detailed and accurate analysis of the pore structure. By quantitatively analyzing the pore size, shape, and distribution of refractory materials, the performance changes of the materials can be effectively monitored, improving the prediction ability of the performance of refractory materials in actual applications. This not only helps optimize the material formula and processing technology but also enhances the application safety and reliability of refractory materials in extreme environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 is a schematic diagram of the working process of the present invention;

[0044] Figure 2 is a detailed flowchart of S1 of the present invention;

[0045] Figure 3 is a detailed flowchart of S2 of the present invention;

[0046] Figure 4 is a detailed flowchart of S3 of the present invention;

[0047] Figure 5 is a detailed flowchart of S4 of the present invention;

[0048] Figure 6 is a detailed flowchart of S5 of the present invention;

[0049] Figure 7 is a detailed flowchart of S6 of the present invention;

[0050] Figure 8 is an industrial CT three-dimensional pore feature map of a selected area of a silica brick sample;

[0051] Figure 9 is a schematic diagram of the industrial CT pore size distribution of a silica brick sample;

[0052] Figure 10 is a ball-and-stick model diagram of the pore structure;

[0053] Figure 11 is an industrial CT three-dimensional pore feature map of a selected area of a zirconia sample;

[0054] Figure 12 Schematic diagram of the industrial CT pore size distribution of a zirconia sample. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0055] The following describes the technical solutions in the present invention with reference to the drawings.

[0056] In the embodiments of the present invention, words such as "exemplarily" and "for example" are used to represent examples, illustrations or explanations. Any embodiment or design solution described as an "example" in the present invention should not be construed as being more preferred or having more advantages than other embodiments or design solutions. Rather, the use of the word "example" is intended to present concepts in a specific manner. In addition, in the embodiments of the present invention, the meaning expressed by "and / or" can be both, or either one of the two.

[0057] To make the technical problems to be solved, technical solutions and advantages of the present invention clearer, the following will be described in detail with reference to the accompanying drawings and specific embodiments.

[0058] Please refer to Figure 1 , embodiments of the present invention provide a method for evaluating the pore structure of refractory materials using industrial CT. The processing flow of this method may include the following steps:

[0059] S1: Select the X-ray source parameters, detector parameters, focal length, etc. of the industrial CT to match refractory materials with different thicknesses, select a matching filter to avoid image noise, identify the internal structure of the refractory materials, and obtain a two-dimensional projection image of the internal structure;

[0060] S2: Based on the two-dimensional projection image of the internal structure, perform a full-range industrial CT scan on the refractory materials. By continuously rotating the refractory materials 360 degrees and gradually collecting multi-angle projection images, verify the integrity of the image data, and obtain a full-range projection data set;

[0061] S3: Use the full-range projection data set to reconstruct a two-dimensional image into a three-dimensional model, use threshold segmentation to extract the pore structure inside the refractory materials, verify the matching degree between the model and the real-time physical properties, and construct a three-dimensional structure model;

[0062] S4: Use the three-dimensional structure model to quantitatively analyze the size, shape and distribution of the pores in the refractory materials, identify the changes in the pore structure performance of the materials, and obtain the pore characteristic analysis results;

[0063] S5: Through the pore characteristic analysis results, conduct an evaluation of the pore quality of the refractory materials, including evaluating the uniformity of the pore structure, analyzing the performance and reliability of the refractory materials in real-time applications, and obtaining the pore quality evaluation results;

[0064] S6: According to the pore quality evaluation results, evaluate the service performance of the refractory materials, evaluate the stability and durability of the refractory materials in a high-temperature environment, and obtain the evaluation results of the pore structure performance of the refractory materials.

[0065] The two-dimensional projection image of the internal structure with gray-scale differences includes the X-ray source parameters of industrial CT, the types of filter plates selected, and the optimized settings for the ray penetration ability of refractory materials. The omnidirectional projection dataset includes the multi-angle X-ray projection images of refractory materials, the resolution and contrast parameters of the images, and the complete image sequence covering multiple parts of refractory materials. The three-dimensional structure model includes the three-dimensional shape of refractory materials, the internal pore structure information, and the positions of pores relative to the periphery of the materials. The pore feature analysis results include the size distribution of pores, shape classification, and spatial distribution map in the materials. The pore quality assessment results include the uniformity score of the pore structure, quality grade, and comparative analysis with the ideal standard. The evaluation results of the pore structure performance of refractory materials include the stability rating under high-temperature environments, durability test results, and recommended application fields.

[0066] Please refer to Figure 2 , for selecting the X-ray source parameters, detector parameters, focal length, etc. of industrial CT to match refractory materials with different thicknesses, and for selecting filter plates to avoid image noise and identify the internal structure of refractory materials, the specific steps for obtaining the two-dimensional projection image of the internal structure are as follows:

[0067] S101: Select the X-ray source parameters of industrial CT, adjust the voltage of the X-rays and detector parameters according to the different thicknesses of refractory materials, test the different voltages and detector parameters to evaluate the penetration ability, and the execution process for obtaining the ray parameter configuration is as follows;

[0068] Selecting appropriate X-ray source parameters is the primary step for industrial CT scanning. The parameters include the selection of voltage and current, which must be precisely adjusted according to refractory materials with different thicknesses to ensure that the penetration ability of the X-rays matches the material thickness. In the experiment, by testing different combinations of voltage and detector parameters on different refractory material thicknesses, the specific impact of the combination on the penetration ability can be evaluated. By testing and analyzing various combinations of voltage and detector parameters, collecting data and making comparisons, the best parameter combination can be found. It can not only test the voltage and detector parameter settings most suitable for a specific material thickness but also, through comparative analysis, determine the influence of different material thicknesses on the X-ray transmissibility. The data will be used to optimize the X-ray parameter configuration to make it more suitable for the detection of refractory materials with different thicknesses, providing solid data support for subsequent scanning operations, ensuring the accuracy and repeatability of the scanning results, and obtaining the ray parameter configuration.

[0069] S102: Based on the ray parameter configuration, analyze the influence of the filter plate material on image noise, compare the effects of filter plates with different materials through experiments, select the filter plate material and thickness with the best noise reduction effect to optimize the image quality, and the execution process for obtaining the filter plate selection result is as follows;

[0070] Analyze the influence of the filter plate material on image noise, compare the effects of filter plates with different materials through experiments, and according to the formula:

[0071]

[0072] In the formula, SNR is the signal-to-noise ratio, P signal represents the signal power, P noise represents the noise power;

[0073] Set the signal power P signal to 5 units, and the noise power P niise to 2 units;

[0074] Calculate according to the signal-to-noise ratio formula:

[0075]

[0076] The results show that selecting a filter plate with a higher signal-to-noise ratio can significantly improve the image quality. In this way, the reduction effects of filter plates with different materials on image noise are experimentally compared, providing data support for selecting the best filter plate. The filter plate selected according to the experimental results can optimize the image quality, obtain a scanned image with higher clarity and lower noise, and provide a reliable image basis for subsequent analysis and applications

[0077] S103: The execution process of using the filter plate selection result to adjust the exposure time and image optimization settings of industrial CT scanning for scanning refractory materials to obtain a two-dimensional projection image of the internal structure is as follows;

[0078] Adjusting the exposure time and image optimization settings becomes the key to improving the scanning effect. In this process, when adjusting the parameters, the characteristics of the refractory materials and the performance of the selected filter plate must be fully considered. Fine-tuning the exposure time can ensure sufficient irradiation of the refractory materials during scanning without affecting the image quality due to overexposure or underexposure. At the same time, optimizing the image settings involves adjusting the software configuration of the scanning device to improve the clarity and contrast of the image. Through adjustment, while ensuring the image quality, the scanning time required can be reduced. By accurately scanning the refractory materials, not only the detailed internal structure of the materials is shown, but also sufficient data information is retained, providing an important basis for further material analysis and quality assessment. The precise execution of this step is crucial for ensuring the high efficiency and high-quality results of the entire scanning process, and a two-dimensional projection image of the internal structure is obtained.

[0079] Please refer to Figure 3 , based on the two-dimensional projection image of the internal structure, perform a full-range industrial CT scan of the refractory materials. By continuously rotating the refractory materials and gradually collecting multi-angle projection images, verify the integrity of the image data. The steps to obtain a full-range projection data set are specifically as follows:

[0080] S201: Based on the two-dimensional projection image of the internal structure, install the refractory material on the industrial CT scanning table and perform positioning. Rotate 360° around the center of the refractory material, and the execution process for obtaining multi-angle positioning records is as follows;

[0081] The operator needs to correctly install the refractory material on the industrial CT scanning table and perform precise positioning to ensure the accuracy of scanning. After starting the full-range rotation mechanism, it will automatically detect the scanning coverage of the refractory material at each angle. This process is crucial because only by ensuring that the refractory material is evenly scanned at each angle can reliable multi-angle positioning records be obtained. The data is very critical for subsequent image reconstruction and quality assessment. By monitoring the scanning process and results, the operator can timely adjust the equipment settings or the material position to ensure high-quality scanning data, which not only improves the dimension and analysis depth of the image but also provides solid data support for the comprehensive assessment of the refractory material and obtains multi-angle positioning records.

[0082] S202: Using the multi-angle positioning records, continuously operate the industrial CT scanning equipment for radiographic exposure, gradually collect the projection images of the refractory material, and adjust the image collection frequency, exposure time, and integration time. The execution process for obtaining multi-angle projection data is as follows;

[0083] The operator needs to continuously operate the industrial CT scanning equipment for full-angle coverage. This step is to ensure that the images of the refractory material can be captured from each estimated angle without missing any estimated details or defects. The gradually collected projection images will be used to construct a comprehensive three-dimensional model. Adjusting the image collection frequency and angle step size is the key to this process to ensure that each step of the image is clear and coherent. By adjusting the frequency and step size, technicians can control the fineness and coverage of the image data. Such an operation not only improves the scanning efficiency but also ensures the comprehensiveness and high quality of the data and obtains multi-angle projection data.

[0084] S203: According to the multi-angle projection data, verify the projection data, check the integrity and consistency of the image data, verify that the data is without missing and abnormalities, and the execution process for generating the full-range projection data set is as follows;

[0085] Validating the projection data, which includes checking the integrity and consistency of the image data to ensure there is no data loss or anomaly, is a crucial step in generating a reliable omnidirectional projection dataset. Technicians carefully inspect and process the collected data using advanced image processing software and algorithms. During the process of verifying the absence of data loss and anomalies, rescanning or adjusting the image data is involved to ensure that each piece of data is accurate and error-free for further in-depth analysis and evaluation, providing a comprehensive understanding of the structure and properties of refractory materials. The accuracy and integrity of the data are directly related to the success of subsequent analysis and are an important guarantee for ensuring the reliability of the results, generating an omnidirectional projection dataset.

[0086] Please refer to Figure 4 , adopt the omnidirectional projection dataset, reconstruct the two-dimensional image into a three-dimensional model, use threshold segmentation to extract the pore structure inside the refractory material, and verify the matching degree between the model and the real-time physical properties. The specific steps for constructing the three-dimensional structure model are as follows:

[0087] S301: Based on the omnidirectional projection dataset, adopt computer image processing technology to reconstruct the two-dimensional image into a three-dimensional model, set the reconstruction parameters (such as median filtering, etc.), optimize the accuracy of the model, and the execution process of obtaining the reconstruction parameter setting record is as follows;

[0088] The technical team reconstructs the two-dimensional image into a three-dimensional model using computer image processing technology. The key steps in this process include setting appropriate parameters to optimize the accuracy of the model. By finely adjusting the parameters, the team can ensure that the three-dimensional model can accurately reflect the actual structure of the refractory material, including all key parameter values and setting details. The record not only helps to understand the technical details of model construction but also provides a reproducible benchmark for future model optimization. Ensuring the high accuracy of the three-dimensional model is crucial for subsequent material analysis and application development, obtaining the reconstruction parameter setting record.

[0089] S302: According to the reconstruction parameter setting record, extract the pore structure inside the refractory material, adjust the image threshold to verify the representation and size consistency of the pores, and the execution process of generating the pore structure detail map is as follows;

[0090] Technicians extract the pore structure inside the refractory material. This step includes adjusting the image threshold to verify the representation and size consistency of the pores. By precisely adjusting the image threshold, it can be ensured that it is consistent with the actual material structure, providing intuitive and detailed information about the internal structure of the material for materials scientists, helping to further analyze the performance and application potential of the material, not only for technical documents but also as the basis for further research and development work, generating the pore structure detail map.

[0091] S303: Using the detailed pore structure diagram, conduct a comparative analysis of the model and real-time physical properties, check the matching degree between the model and the entity, and the execution process of constructing the three-dimensional structure model is as follows;

[0092] When using the detailed pore structure diagram to conduct a matching analysis between the model and the entity, key features need to be extracted from high-precision microscopic imaging data. These features include the size, shape, and distribution pattern of the pores. Next, use advanced image processing software to quantitatively analyze these features to ensure the accuracy and repeatability of the data. Through processing, the model will be used to compare with the actual physical sample to verify the accuracy of the model. In the comparative analysis, the geometric parameters of the pores will be compared in detail with the entity sample to analyze the matching degree and existing deviations. This process includes not only intuitive visual comparison but also the application of mathematical models and statistical methods to quantify the differences between the model and the entity. Through comparison, necessary adjustments and optimizations can be made to the model to ensure that it can better reflect the physical properties of the entity, thereby obtaining a scientific evaluation of the matching degree between the model and the entity and constructing the three-dimensional structure model.

[0093] Please refer to Figure 5 , using the three-dimensional structure model, to quantitatively analyze the size, shape, and distribution of the pores in the refractory material, identify the changes in the pore structure performance of the material, and the steps to obtain the pore characteristic analysis results are specifically as follows:

[0094] S401: Based on the three-dimensional structure model, measure the size and shape of the pores in the refractory material, collect multi-dimensional data of the pores in the refractory material, and the execution process of obtaining the pore size data is as follows;

[0095] Measure the size and shape of the pores in the refractory material, including obtaining a detailed three-dimensional image of the refractory material through CT technology and accurately measuring the size and shape of the pores. In this process, the collected three-dimensional image data needs to be processed, such as using image processing software to identify and quantify the specific dimensions of the pores, including the width, length, and shape of the pores, and using image analysis algorithms to evaluate the distribution and spatial location of the pores. Collecting and analyzing the data not only helps to understand the microstructure of the refractory material but is also crucial for studying physical and chemical properties. For example, by analyzing how the pores affect the thermal stability and mechanical strength of the material, obtain the pore size data.

[0096] S402: According to the pore size data, iteratively analyze the distribution characteristics of the pores in the refractory material, statistically analyze the spatial distribution law and frequency of the pores in the refractory material, analyze the pore distribution in the refractory material, and the execution process of obtaining the pore distribution identification result is as follows;

[0097] Statistically analyze the spatial distribution law and frequency of the pores in the refractory material, according to the formula:

[0098]

[0099] In the formula, P(d) represents the probability density of pores with a diameter of d, μ represents the average value of the pore diameter, σ represents the standard deviation of the pore diameter, and e is the natural constant;

[0100] The pore distribution follows a normal distribution, where μ and σ are calculated through statistical methods such as the least squares method based on actual data, and μ = 100 microns and σ = 15 microns are set;

[0101] Then the pore probability distribution with a diameter of 120 microns can be calculated:

[0102]

[0103] This result indicates that in the statistical sample, the probability of pores with a diameter of 120 microns appearing is 2.4%, which helps to further understand the pore distribution characteristics of the material and predict its performance.

[0104] S403: Through the pore distribution analysis results, combined with the data on the pore size, shape, and distribution of refractory materials, evaluate and identify the changes in the pore structure performance of refractory materials. The execution process for obtaining the pore characteristic analysis results is as follows;

[0105] Evaluate and identify the changes in the pore structure performance of refractory materials, which includes combining the previous distribution characteristic results with the specific shape and size data of pores, and evaluating how pores affect the overall performance of the material through models and algorithms. Multiple statistical and modeling techniques are involved in this execution process. For example, multiple regression analysis is used to explore the correlation between pore size, shape, and material performance, and machine learning methods such as random forest or support vector machine are used for more in-depth data mining to identify the potential association between pore characteristics and the decline in refractory material performance. The analysis results help to optimize the manufacturing process of the material and enhance the refractory performance of the material by improving the pore distribution, and obtain the pore characteristic analysis results.

[0106] Please refer to Figure 6 , through the pore characteristic analysis results, conduct the pore quality assessment of refractory materials, including evaluating the uniformity of the pore structure, analyzing the performance and reliability of refractory materials in real-time applications. The specific steps for obtaining the pore quality assessment results are as follows:

[0107] S501: According to the pore characteristic analysis results, collect and calculate the uniformity index of the pore structure, numerically evaluate the regularity and uniformity of the pores, and the execution process for obtaining the pore uniformity assessment result is as follows;

[0108] The operator needs to collect and calculate the uniformity index of the pore structure of the refractory material. This process involves using statistical methods to evaluate the regularity and uniformity of the pores. By performing numerical analysis on the size, shape, and distribution of the pores in the material, the uniformity of the internal pore distribution of the material is reflected, which is crucial for evaluating the structural integrity and performance stability of the material. The level of the uniformity index directly affects the mechanical properties and durability of the material. Therefore, accurate uniformity evaluation is very critical for optimizing the material design and manufacturing process to ensure that the material can maintain the expected performance standards under various application conditions and obtain the pore uniformity evaluation results.

[0109] S502: Based on the pore uniformity evaluation results, combined with the usage environment and application conditions of the refractory material, simulate the real-time application scenario, and analyze the performance of the refractory material under the expected working conditions. The execution process for generating the real-time application performance analysis results is as follows;

[0110] Combined with the usage environment and application conditions of the refractory material, simulate the real-time application scenario, according to the formula:

[0111]

[0112] In the formula, R represents the expected performance score of the material, n i represents the numerical evaluation of each pore parameter i, p i represents the weight coefficient of this parameter, and N represents the number of all evaluation parameters;

[0113] There are five evaluation parameters set, and the numerical evaluations n i of each parameter are 2, 3, 4, 5, 3 respectively, and the corresponding weight coefficients p i are 0.1, 0.2, 0.3, 0.2, 0.2,

[0114] Calculate according to the formula:

[0115]

[0116] This kind of evaluation helps to understand the performance of the material in actual use and provides data support for further application and optimization.

[0117] S503: According to the real-time application performance analysis results, evaluate the overall quality and reliability of the refractory material, and refer to the performance stability and long-term reliability of the material in real-time application. The execution process for obtaining the pore quality evaluation results is as follows;

[0118] Technicians need to evaluate the overall quality and reliability of refractory materials. This evaluation process includes referring to the performance stability and long-term reliability of the materials in actual applications. By comprehensively considering the performance of refractory materials under various environmental conditions, it is an important indicator for judging whether the materials meet the application requirements. Since the reliability of the materials is directly related to their durability in high-temperature or high-pressure environments, the evaluation results can also provide directions for material improvement and process optimization to ensure that the performance of the materials meets the requirements of specific applications. The entire evaluation process increases the depth of the comprehensive understanding of the material performance, provides important information on the long-term application probability of the materials, and obtains the pore quality evaluation results.

[0119] Please refer to Figure 7 , according to the pore quality evaluation results, to evaluate the stability and durability of refractory materials in high-temperature environments, the steps to obtain the evaluation results of the pore structure performance of refractory materials are as follows:

[0120] S601: Using the pore quality evaluation results, conduct environmental simulation, set high-temperature condition parameters, and test the stability and durability of refractory materials in the simulated high-temperature environment. Record the reactions and performance changes of the refractory materials to obtain the execution process of the high-temperature environment test results as follows;

[0121] The technical team conducts environmental simulation and precisely sets high-temperature condition parameters to test the stability and durability of refractory materials in the simulated high-temperature environment. This test process involves placing the refractory materials in the simulated high-temperature environment and recording the response of the materials to high temperature and any changes in performance, including structural deformation, strength decline, or chemical property changes. The data will be used to evaluate the behavior and reliability of the materials in actual high-temperature applications. The recorded results will show the performance of the materials under extreme conditions and provide key data for further improvement and application of the materials. The information is crucial for developing refractory materials suitable for specific high-temperature applications, and the high-temperature environment test results are obtained.

[0122] S602: Based on the high-temperature environment test results, conduct data analysis on the performance attenuation and structural loss of refractory materials, and calculate the real-time durability of refractory materials. The execution process to obtain the durability adjustment plan is as follows;

[0123] The formula for calculating the real-time durability of refractory materials is:

[0124]

[0125] Among them, is the expected durability of the material, β0 represents the intercept of the regression line, β1, β2, β3, and β4 are the coefficients adjusted for temperature, time, material composition, and material density respectively, T represents the test temperature, t represents the exposure time, C is the percentage of specific chemical components of the material, and B represents the material density;

[0126] Parameter meaning and setting value:

[0127] β0=2.5, represents the basic durability, the default value when not affected by high temperature, and is based on the average value of historical test data;

[0128] T is the test temperature, and the set value is 1600℃. This value is within the common high temperature test range under experimental conditions and reflects the performance changes of the material under high temperature;

[0129] t is the exposure time, which is set to 24 hours. The exposure time is based on the standard fire resistance test duration and reflects the material's ability to withstand high temperatures for a long time.

[0130] is the square root conversion value of the material composition, and C is set to be the percentage of the material's specific chemical composition, such as the magnesium aluminum spinel content. If the magnesium aluminum spinel content is set to 20%, then Emphasize the influence of the proportion of magnesium-aluminum spinel in the material on durability;

[0131] represents the coefficient adjusted by the material density, where β4=0.5 is a fixed coefficient and B is the density of the material, which is set to 2.5, which is the typical density value of the material in a high temperature environment;

[0132] Substitute the parameters into the formula for calculation:

[0133]

[0134] The results show that under the given test conditions, the expected durability of the material is 51.85, which reflects the fire resistance of the material in the high temperature environment and within a specific time. The result is used to determine whether the material meets the safety standards and provides a basis for further improvement of the material.

[0135] S603: Implement the durability adjustment plan, evaluate the ability of refractory materials in differentiated industrial environments, verify the optimization of refractory material applications and performance, and obtain the evaluation results of refractory material pore structure performance. The execution process is as follows;

[0136] In the process of implementing the durability adjustment plan, the team will evaluate the performance capabilities of refractory materials in differentiated industrial environments, which includes adjusting the application areas and processing methods to verify the optimization of refractory materials in different applications and performance. The purpose of this work is to determine the best performance and applicability of materials in various industrial environments. Through adjustments, the key performance parameters and application areas of the materials can be identified to ensure that the refractory materials can achieve optimal performance in the predetermined application environment, guide material scientists and engineers to further optimize the material formulation and processing technology, ensure that the quality and performance of the materials can meet the needs of a wider range of industrial applications, and obtain the evaluation results of the pore structure performance of refractory materials.

[0137] Please refer to Figure 8 、 9 、10, Example 1: CT pore structure characterization of siliceous refractory materials

[0138] CT scanning parameters: tube voltage: 120 kV, tube current: 100 μA, detector energy 1 Pf, integration time: 1 s, filter: none.

[0139] Select a Ф10 mm × 10 mm silicon brick cylindrical sample and fix it in the center of the sample rotating stage. Rotate the sample stage 360° steadily without shaking. Close the lead door and turn on the X-ray source to obtain an internal structure image with gray-scale characteristics. Adjust the sample position and detector distance according to the image to make the magnification 20 times, and the image is within the detector range during rotation. Based on the internal structure image, perform a circular scan on the silicon brick refractory material. The number of scan sheets is 1800, and rotate 360° to obtain an omnidirectional projection data set. Set the reconstruction parameters for three-dimensional image reconstruction, extract the internal pore structure of the refractory material, construct a three-dimensional structure model, and quantitatively analyze the volume, diameter, surface area, sphericity, and distribution of the pores to obtain the corresponding images and data.

[0140] Result display

[0141] 1. CT two-dimensional pore structure diagram: Display the slice images of different density regions inside the sample.

[0142] 2. CT three-dimensional extraction diagram of pore structure: Reconstruct the three-dimensional morphology of the pores in the sample through the segmentation algorithm, showing the pore shape and connectivity.

[0143] 3. Ball-and-stick model diagram of pore structure: Simplify the pores using the ball-and-stick model to intuitively display the spatial distribution of the pores.

[0144] 4. Pore distribution table: Pore size range (mm): 0 - 0.2, 0.2 - 0.4, 0.4 - 0.6, and the corresponding volume ratios are 2%, 0.5%, 0.1% respectively, and the proportion of through pores is 97.3%.

[0145] Table 1 Proportion of different pore sizes in the silicon brick sample

[0146] Pore size range (diameter, mm) Volume percentage (%) ≤0.2 2.1 0.2～0.4 0.5 0.4～0.6 0.1 0.6～1.0 - 1.0＜ 97.3

[0147] Please refer to Figure 11 、 12 , Example 2: CT pore structure characterization of zirconia refractory materials

[0148] CT scanning parameters: tube voltage: 225 kV, tube current: 80 μA, detector energy 2 Pf, integration time: 1 s, filter: 1 mm Cu.

[0149] A 10mm×10mm×10mm zirconia sample was fixed at the center of the sample rotating stage. The sample stage was rotated 360° steadily without shaking. The lead door was closed and the X-ray source was turned on to obtain an internal structure image with gray-scale characteristics. The position of the sample and the distance to the detector were adjusted according to the image to achieve a magnification of 20 times, and the image was within the detector range during the rotation. A circular scan was performed on the silica brick refractory material based on the internal structure image. The number of scan sheets was 2,160, and a full-range projection data set was obtained by rotating 360°. Reconstruction parameters were set for three-dimensional image reconstruction, the internal pore structure of the refractory material was extracted, a three-dimensional structure model was constructed, and the volume, diameter, surface area, sphericity, and distribution of the pores were quantitatively analyzed to obtain the corresponding images and data.

[0150] Result display

[0151] CT two-dimensional map of pore structure: The sliced image of the zirconia sample, with the pore distribution of the high-density material highlighted in the key area.

[0152] CT three-dimensional extraction map of pore structure: Reconstruct the three-dimensional morphology of the pore structure of the zirconia material.

[0153] Pore distribution table: The pore size distribution is mainly ≤0.2mm, accounting for 10.9%, and the through pores account for 66.73%.

[0154] Table of proportion of different pore sizes in the zirconia sample

[0155] Pore size range (diameter, mm) Volume percentage (%) ≤0.2 10.9 0.2～0.4 9.0 0.4～0.6 5.1 0.6～1.0 8.3 1.0＜ 66.7

[0156] As described above, it is only the specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention can easily think of changes or substitutions, which should all be covered within the protection scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope of the claimed rights.

Claims

1. A method for evaluating the pore structure of refractory materials using industrial CT, characterized in that: The following steps are involved: S1: Select the X-ray source parameters, detector parameters, focal length, etc. of the industrial CT to match the refractory materials with differentiated thickness, select filters to avoid image noise, identify the internal structure of the refractory materials, and obtain a two-dimensional projection image of the internal structure with grayscale differences; S2: Based on the two-dimensional projection image of the internal structure, a full-scale industrial CT scan is performed on the refractory material, and the integrity of the image data is verified by continuously rotating the refractory material and gradually collecting multi-angle projection images to obtain a full-scale projection data set; S3: using the omnidirectional projection data set, reconstructing the two-dimensional image into a three-dimensional model, using threshold segmentation to extract the pore structure inside the refractory material, verifying the matching degree between the model and the real-time physical properties, and constructing a three-dimensional structural model; S4: using the three-dimensional structural model, quantitatively analyzing the size, shape and distribution of the pores of the refractory material, identifying changes in the pore structure performance of the material, and obtaining pore characteristic analysis results; S5: Based on the pore characteristic analysis results, the pore quality of the refractory material is evaluated, including evaluating the uniformity of the pore structure, analyzing the performance and reliability of the refractory material in real-time applications, and obtaining a pore quality evaluation result; S6: Based on the pore quality evaluation results, the stability and durability of the refractory material in a high temperature environment are evaluated to obtain the pore structure performance evaluation results of the refractory material.

2. The method for evaluating the pore structure of refractory materials using industrial CT according to claim 1, characterized in that: The two-dimensional projection image of the internal structure with grayscale difference includes the X-ray source parameters of the industrial CT, the detector parameters, the type of filter selected, and the optimized settings for the ray penetration ability of the refractory material. The omnidirectional projection data set includes multi-angle X-ray projection images of the refractory material, the resolution and contrast parameters of the image, and a complete image sequence covering multiple parts of the refractory material. The three-dimensional structural model includes the three-dimensional morphology of the refractory material, the internal pore structure information, and the position of the pores and the periphery of the material. The pore characteristic analysis results include the size distribution, shape classification, and spatial distribution map of the pores in the material. The pore quality assessment results include the uniformity score of the pore structure, the quality grade, and the comparative analysis with the ideal standard. The refractory material pore structure performance evaluation results include the stability rating in a high temperature environment, the durability test results, and the recommended application areas.

3. The method for evaluating the pore structure of refractory materials using industrial CT according to claim 1, characterized in that: The specific steps of selecting the industrial CT X-ray source parameters, detector parameters, focal length, etc. to match the refractory materials with different thicknesses, selecting filters to avoid image noise, identifying the internal structure of the refractory materials, and obtaining the two-dimensional projection image of the internal structure are as follows: S101: Select X-ray source parameters of industrial CT, adjust X-ray voltage and detector parameters according to the differentiated thickness of refractory materials, test differentiated voltage and detector parameters to evaluate penetration capability, and obtain ray parameter configuration; S102: Based on the ray parameter configuration, analyzing the influence of the filter material on the image noise, comparing the effects of filters with different materials through experiments, selecting the filter material and thickness with the best noise reduction effect, optimizing the image quality, and obtaining the filter selection result; S103: using the filter selection result, adjusting the exposure time and image optimization settings of the industrial CT scan, scanning the refractory material, and obtaining a two-dimensional projection image of the internal structure.

4. The method for evaluating the pore structure of refractory materials using industrial CT according to claim 1, characterized in that: Based on the two-dimensional projection image of the internal structure, a full-scale industrial CT scan is performed on the refractory material. By continuously rotating the refractory material and gradually collecting multi-angle projection images, the integrity of the image data is verified. The steps of obtaining a full-scale projection data set are specifically as follows: S201: Based on the two-dimensional projection image of the internal structure, the refractory material is installed on the industrial CT scanning table, and positioned, and the refractory material is rotated 360° around the center of the refractory material to obtain multi-angle positioning records; S202: using the multi-angle positioning record, continuously operating the industrial CT scanning equipment to perform radiographic transillumination, gradually collecting projection images of the refractory material, adjusting the image collection frequency, exposure time, and integration time, and obtaining multi-angle projection data; S203: Verify the projection data according to the multi-angle projection data, check the integrity and consistency of the image data, verify that the data is free of omissions and anomalies, and generate a full-range projection data set.

5. The method for evaluating the pore structure of refractory materials using industrial CT according to claim 1, characterized in that: The steps of reconstructing the 2D image into a 3D model using the omnidirectional projection data set, extracting the pore structure inside the refractory material using threshold segmentation, and verifying the matching degree between the model and the real-time physical properties are as follows: S301: Based on the omnidirectional projection data set, using computer image processing technology, reconstructing the two-dimensional image into a three-dimensional model, setting reconstruction parameters, optimizing the accuracy of the model, and obtaining a reconstruction parameter setting record; S302: extracting the pore structure inside the refractory material according to the reconstruction parameter setting record, adjusting the image threshold to verify the representation and size consistency of the pores, and generating a pore structure detail map; S303: Using the pore structure detail map, a comparative analysis is performed between the model and the real-time physical properties, the matching degree between the model and the entity is checked, and a three-dimensional structure model is constructed.

6. The method for evaluating the pore structure of refractory materials using industrial CT according to claim 1, characterized in that: The steps of using the three-dimensional structural model to quantitatively analyze the size, shape and distribution of the pores of the refractory material, identify the changes in the pore structure performance of the material, and obtain the pore characteristic analysis results are specifically as follows: S401: Based on the three-dimensional structure model, the size and shape of the pores of the refractory material are measured, and multi-dimensional data of the pores of the refractory material are collected to obtain pore size data; S402: iteratively analyzing the distribution characteristics of the pores of the refractory material according to the pore size data, statistically analyzing the spatial distribution law and frequency of the pores of the refractory material, analyzing the pore distribution of the refractory material, and obtaining a pore distribution identification result; S403: By using the pore distribution analysis results and combining the data on the pore size, shape and distribution of the refractory material, the changes in the pore structure performance of the refractory material are evaluated and identified to obtain the pore characteristic analysis results.

7. The method for evaluating the pore structure of refractory materials using industrial CT according to claim 1, characterized in that: The pore quality of the refractory material is evaluated by the pore characteristic analysis results, including evaluating the uniformity of the pore structure and analyzing the performance and reliability of the refractory material in real-time applications. The specific steps for obtaining the pore quality evaluation results are as follows: S501: According to the pore characteristic analysis results, collect and calculate the uniformity index of the pore structure, perform numerical evaluation on the regularity and uniformity of the pores, and obtain a pore uniformity evaluation result; S502: Based on the pore uniformity evaluation result, combined with the use environment and application conditions of the refractory material, simulate the real-time application scenario, analyze the performance of the refractory material under the expected working conditions, and generate a real-time application performance analysis result; S503: According to the real-time application performance analysis results, the overall quality and reliability of the refractory material are evaluated, and the pore quality evaluation results are obtained by referring to the performance stability and long-term reliability of the material in real-time applications.

8. The method for evaluating the pore structure of refractory materials using industrial CT according to claim 1, characterized in that: According to the pore quality evaluation results, the stability and durability of the refractory material in a high temperature environment are evaluated, and the steps of obtaining the evaluation results of the pore structure performance of the refractory material are specifically as follows: S601: using the pore quality assessment result, performing environmental simulation, setting high temperature condition parameters, testing the stability and durability of the refractory material in the simulated high temperature environment, recording the reaction and performance change of the refractory material, and obtaining the high temperature environment test result; S602: Based on the high temperature environment test results, analyze the refractory material performance attenuation and structural loss data, calculate the real-time durability of the refractory material, and obtain a durability adjustment plan; S603: Implement the durability adjustment plan, evaluate the capabilities of refractory materials in differentiated industrial environments, verify the optimization of refractory material applications and performance, and obtain refractory material pore structure performance evaluation results.

9. The method for evaluating the pore structure of refractory materials using industrial CT according to claim 8, characterized in that: The formula for calculating the real-time durability of the refractory material is: in, is the expected durability of the material, β0 represents the intercept of the regression line, β1, β2, β3 and β4 are the coefficients of adjustment for temperature, time, material composition and material density, respectively, T represents the test temperature, t represents the exposure time, C represents the percentage of specific chemical composition of the material, and B represents the material density.

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