Method of extending irregular shaped materials

Abstract

To provide a method for extension-constructing an indeterminate form material, capable of sufficiently adhering the indeterminate form material to a base material, while suppressing a decrease in construction efficiency and an increase in construction costs, when extension-constructing the indeterminate form material to the base material.SOLUTION: A method for extension-constructing an indeterminate form material to a surface of a base material includes: a roughness adjustment step of adjusting surface roughness of the base material to make a standard deviation of the surface roughness of the base material 500 μm or more; and a construction step of extension-constructing a new indeterminate form material to the surface of the base material whose surface roughness has been adjusted in the roughness adjustment step.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a method for adding on unshaped materials, and more particularly to a method for adding on unshaped materials by adding new unshaped materials of the same material to damaged areas of hardened unshaped materials. [Background technology]

[0002] Monolithic materials have fluidity and are constructed by mixing raw materials, admixtures, and water at the construction site and pouring them into the construction area under certain conditions. Because of their fluidity, monolithic materials can be easily molded into complex shapes, and can be constructed without highly skilled workers. For this reason, monolithic materials are widely used in a variety of fields, such as monolithic refractory linings for high-temperature furnaces and molten metal vessels, and in concrete and cement used in construction and civil engineering projects.

[0003] Depending on the application and use conditions of the monolithic refractory, new monolithic refractory may be added to the surface of the already hardened monolithic refractory. For example, in the case of a monolithic refractory lining a molten metal vessel, it is subject to contact with high-temperature molten metal, erosion by molten slag, sudden temperature changes, physical impacts, and the like. Because monolithic refractory linings of molten metal vessels are always used under such harsh conditions, they may suffer from erosion and other damage. When erosion of the monolithic refractory occurs, in order to reduce manufacturing costs, waste emissions, and environmental impact, rather than replacing the entire lining, a monolithic refractory repair may be added only to the eroded area, i.e., a monolithic refractory replenishment process. When such replenishment of the monolithic refractory is performed, high adhesive strength is always required at the interface of the replenished surface of the monolithic refractory.

[0004] Various measures have been proposed to prevent the joining surface of monolithic materials from becoming brittle, i.e., to increase the adhesive strength of the joining interface of monolithic materials. For example, Patent Documents 1 and 2 describe a technique for improving the adhesive strength of the interface by applying a coating material such as an inorganic salt paste or liquid silicone resin to the surface of the base material to be joined, and then pouring in monolithic refractory. Patent Document 3 describes a method for filling the damaged area with monolithic refractory by inserting monolithic refractory into multiple holes drilled at any position in the damaged area. Drilling multiple holes increases the surface area of ​​the adhesive interface, which is said to improve the adhesive strength of the interface. Furthermore, Patent Document 4, as a related technology, proposes a system for evaluating the degree of unevenness of a joint surface using an unevenness evaluation device when treating the surface of previously poured and hardened concrete before pouring new concrete. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 7-9118 [Patent Document 2] Japanese Patent Application Publication No. 10-274485 [Patent Document 3] Japanese Patent Application Publication No. 54-96506 [Patent Document 4] Patent Publication No. 2021-25220 Summary of the Invention [Problem to be solved by the invention]

[0006] In Patent Documents 1 and 2, a coating material needs to be applied to the surface of the base material, which requires a lot of processing time, reduces construction efficiency, and may increase construction costs. In Patent Document 3, a large number of holes are drilled and shaped refractories are charged, which presents the same problems as Patent Documents 1 and 2. In addition, because the adhesive strength at the interface varies depending on the material of the unshaped material, the technology in Patent Document 4 may not be able to determine whether the adhesive strength at the interface is sufficient. In these respects, there is still room for improvement.

[0007] The present invention has been made to solve the above-mentioned problems, and aims to provide a method for adding irregular materials that can sufficiently adhere the irregular materials to the base material while suppressing a decrease in construction efficiency and an increase in construction costs when adding the irregular materials to the base material. [Means for solving the problem]

[0008] In order to achieve the above object, the present invention provides: [1] A method for adding irregular material to the surface of a base material, comprising a roughness adjustment step for adjusting the surface roughness of the base material to make the standard deviation of the surface roughness of the base material 500 μm or more, and a construction step for adding new irregular material to the surface of the base material whose roughness has been adjusted in the roughness adjustment step. [2] In the roughness adjustment process, the surface roughness of the base material is adjusted while removing surface deposits on the surface of the base material before the amorphous material is added, or the surface roughness of the base material is adjusted after removing surface deposits on the surface of the base material before the amorphous material is added. [1] A method for adding amorphous material described in [1]. [3] After adjusting the surface roughness of the base material in the roughness adjusting step, a 0.010 g / cm 2 More than 0.250g / cm 2 A method for adding and constructing irregular materials according to [1] or [2], which includes a water application process for attaching the following water. [4] A method for extending and constructing irregular materials as described in [1] or [2], wherein the adhesive strength between the new irregular material and the surface of the base material after adjusting the surface roughness of the base material in the roughness adjustment process is at least 50% or more of the bending strength of the base material. [5] The method for extending and constructing an amorphous material described in [1] or [2], wherein the amorphous material is a graphite-containing amorphous refractory material containing graphite. [6] A method for adding on amorphous materials described in [5], in which the roughness adjustment process adjusts the surface roughness based on the graphite content of the graphite-containing amorphous refractory material. [Effects of the Invention]

[0009] In the method for adding monolithic materials according to the present invention, the surface roughness of the base material is adjusted to a standard deviation of 500 μm or more. This allows for sufficient adhesion between the new monolithic material and the base material when it is added. Furthermore, adjusting the surface roughness of the base material to a standard deviation of 500 μm or more increases the adhesive strength. Therefore, compared to methods for increasing adhesive strength by applying a coating material to the surface of the new monolithic material to be added or by drilling multiple holes and inserting shaped refractories, this method is easier to install because it does not require the application of a coating material or the insertion of shaped refractories. This prevents a decrease in installation efficiency and further reduces installation costs. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 2 is a partial cross-sectional view of a molten metal container. [Figure 2] FIG. 1 is a diagram showing an example of a surface roughness measuring device that quantifies the standard deviation of the surface roughness of the remaining refractory material. [Figure 3] FIG. 10 is a diagram showing the relationship between the standard deviation of the surface roughness of the remaining refractory and the proportion of the adhesive strength in the original bending strength of the workpiece refractory layer. DETAILED DESCRIPTION OF THE INVENTION

[0011] The present invention will be described below through embodiments of the present invention. FIG. 1 is a partial cross-sectional view of a molten metal vessel using an unshaped material according to this embodiment, and FIG. 1(A) shows the molten metal vessel (hereinafter simply referred to as the vessel) before topping up. The vessel is a vessel that holds molten metal (not shown) inside. Specific examples of the vessel include vessels that hold or refine molten metal such as molten pig iron or molten steel, and vessels that transport these. The vessel has a steel shell 1 that forms an outer shell and is made of iron or an iron-based material. A permanent mortar layer 2 is formed inside the steel shell 1, and a workpiece refractory layer 3 is formed inside the permanent mortar layer 2. The vessel shown in FIG. 1 has a multi-layer structure that is composed of the steel shell 1, the permanent mortar layer 2, and the workpiece refractory layer 3, in this order from the outside.

[0012] The permanent brick layer 2 is formed by arranging permanent bricks in layers. Examples of the permanent bricks that can be used include roseki, zircon, clay, chamotte, high alumina, alumina, spinel, SiC, and bricks made of a combination of two or more of these.

[0013] The workpiece refractory layer 3 is made of the monolithic material in this embodiment. Specifically, the monolithic material is a graphite-containing monolithic refractory material containing graphite, and may be a conventionally known material.

[0014] When molten metal (sometimes referred to as "molten metal") is supplied to a vessel having the above-described configuration, the molten metal comes into contact with the workpiece refractory layer 3 that forms the inner surface of the vessel. The temperature of the molten metal is, for example, as high as approximately 1000°C. Therefore, when the vessel shown in FIG. 1A is repeatedly used, the workpiece refractory layer 3 gradually wears away. Specifically, due to temperature changes accompanying the supply and discharge of molten metal to the vessel, the unshaped material that forms the workpiece refractory layer 3 expands and contracts, generating thermal stress. Furthermore, when the workpiece refractory layer 3 is exposed to high-temperature molten metal, the unshaped material that forms the workpiece refractory layer 3 is chemically eroded by the slag, since the molten metal contains slag. This erosion layer of the unshaped material and the repeatedly occurring thermal stress gradually deteriorate the workpiece refractory layer 3, causing wear and tear.

[0015] Thus, after repeated use, slag adheres to the inner surface of the vessel, i.e., the inner surface of the workpiece refractory layer 3, as an attachment, or the attached slag infiltrates the unshaped material, forming an altered layer. Here, "slag" refers to a by-product whose main raw material is oxide, which is generated in the process of removing impurities such as carbon, phosphorus, and sulfur from molten metal. In this embodiment, the attachment and the altered layer are collectively referred to as the surface layer attachment 4. Furthermore, the remaining portion of the workpiece refractory layer 3 located below the surface layer attachment 4 is referred to as the remaining refractory 5.

[0016] If new cast iron is added to the surface of the workpiece refractory layer 3 while the surface layer deposit 4 remains, the surface layer deposit 4 becomes weak, potentially reducing the adhesive strength of the newly added cast iron to the inner surface of the container. This is due to differences in physical properties between the newly added cast iron and the surface layer deposit 4. Therefore, for example, if a container is used to which new cast iron has been added without removing the surface layer deposit 4, cracks may occur on the added surface, i.e., in the newly added cast iron. Furthermore, molten metal may penetrate between the newly added cast iron and the surface layer deposit 4, causing cracks to propagate. The newly added cast iron may then peel off at the boundary between the newly added cast iron and the surface layer deposit 4. This reduces the durability of the container. That is, a vessel in which new monolithic material is added without removing surface deposits 4 will have a significantly reduced lifespan compared to a molten metal vessel in which a new work refractory layer 3 is re-lined or a brand new molten metal vessel, and therefore the cost benefit of repairing the vessel by adding material will be reduced.

[0017] Therefore, in the method for adding monolithic material according to this embodiment, the surface deposits 4 are scraped off and removed before adding new monolithic material to the surface of the workpiece refractory layer 3. In addition, the surface roughness of the workpiece refractory layer 3 is adjusted so that the standard deviation of the surface roughness of the surface of the workpiece refractory layer 3 is 500 μm or more. This improves the adhesive strength of the newly added monolithic material to the inner surface of the container.

[0018] (Removal process) The surface deposit 4 may be removed by peeling it off using, for example, a hammer or an ice axe. Alternatively, the surface deposit 4 may be removed by grinding it using a machine such as a heavy machine or a hydraulic drafter. Fig. 1(B) shows a state in which the surface deposit 4 on the surface of the workpiece refractory layer 3 has been scraped off and removed.

[0019] The surface deposit 4 is a damaged area where slag has adhered and an altered layer has formed, and can be identified visually or by analyzing image data captured by a camera. In other words, the color of amorphous material that does not contain carbon (graphite) is white, while the color of amorphous material that contains carbon (graphite) is dark gray. On the other hand, the color of slag is tar-like black. Thus, the surface deposit 4 and the workpiece refractory layer 3 differ in color and texture. Therefore, they can be distinguished by visual inspection or image analysis.

[0020] It is preferable to remove the surface layer deposits 4 until the remaining refractory 5 located underneath is exposed. If no surface layer deposits 4 are present on the surface of the workpiece refractory layer 3, the roughness adjusting step may be carried out without any particular removal work.

[0021] (Roughness adjustment process) With the remaining refractory 5 exposed, the surface roughness of the remaining refractory 5 is adjusted. Specifically, the surface roughness of the remaining refractory 5, i.e., the degree of surface irregularity on the surface of the remaining refractory 5, is measured, and the measured surface roughness is quantified as the standard deviation of the height distribution of the surface irregularities. The surface roughness of the remaining refractory 5 is then adjusted so that the standard deviation is equal to or greater than a predetermined threshold. FIG. 1C shows the state in which the surface roughness of the remaining refractory 5 has been adjusted as described above. In this way, as shown in FIG. 1C, an interface 6 is formed in which the surface of the remaining refractory 5 is roughened. This is because increasing the standard deviation of the surface roughness increases the contact area between the remaining refractory 5 and the newly added monolithic refractory, thereby increasing the adhesive strength therebetween. Furthermore, increasing the standard deviation of the surface roughness reduces the proportion of coarse aggregate in the monolithic refractory at the added surface, thereby increasing the exposed surface area of ​​cement. This is to increase the effective surface area for bonding of the cement in the monolithic refractory, thereby increasing the adhesive strength.

[0022] A more detailed explanation will be given. FIG. 2 is a diagram showing an example of a surface roughness measuring device that quantifies the standard deviation of the surface roughness of the remaining refractory 5. The surface roughness measuring device 7 shown in FIG. 2 is mainly composed of a microcomputer, and has an image data acquisition unit 8, a 3D model generation unit 9, a standard deviation calculation unit 10, a standard deviation determination unit 11, and an output unit 12. The image data acquisition unit 8 is connected via a wire or wirelessly to a camera 13 that photographs the surface of the remaining refractory 5, and acquires image data output from the camera 13. That is, in this embodiment, the camera 13 photographs the surface of the remaining refractory 5 to acquire multiple image data, and the image data is output to the surface roughness measuring device 7. The image data acquisition unit 8 also outputs the acquired image data to the 3D model generation unit 9.

[0023] The 3D model generation unit 9 performs calculations based on the image data captured by the camera 13 and pre-stored data and programs to generate a 3D model image of the surface of the remaining refractory 5. That is, the 3D model generation unit 9 performs image processing to generate a 3D model image based on the image data acquired by the camera 13. This image processing may be conventionally known. The 3D model image generated by the 3D model generation unit 9 is output from the 3D model generation unit 9 to the calculation unit 10.

[0024] The surface of the remaining refractory 5 has a mountain-valley structure over a wide range, resulting in a surface with variations in elevation. Therefore, the calculation unit 10 calculates the standard deviation of the surface roughness of the remaining refractory 5 as a statistical quantity of the fracture surface height direction distribution based on the profile of the 3D model image. The standard deviation is output from the calculation unit 10 to the determination unit 11. The determination unit 11 determines whether the standard deviation is equal to or greater than a predetermined threshold, and outputs the determination result together with the standard deviation to the output unit 12. The output unit 12 is, for example, a monitor, and displays the above-mentioned standard deviation and the determination result.

[0025] Then, while checking the standard deviation of the surface roughness of the remaining portion refractory 5 displayed on the output unit 12, the surface roughness of the remaining portion refractory 5 is adjusted so that the standard deviation is equal to or greater than a predetermined threshold. The threshold for the standard deviation is, for example, 500 μm. By setting the standard deviation of the surface roughness to 500 μm or greater, the adhesive strength can be increased to 50% or greater of the original strength of the workpiece refractory layer 3. The relationship between the standard deviation of the surface roughness and the adhesive strength can be determined experimentally. The strength of the workpiece refractory layer 3 refers to the bending strength (sometimes referred to as breaking strength) of the workpiece refractory layer 3 when a three-point support bending test is performed on the workpiece refractory layer 3. The method for calculating the standard deviation of the surface roughness and the adhesive strength will be described in detail in the examples below.

[0026] The surface roughness of the remaining refractory 5 may be adjusted in a manner similar to that of removing the surface deposit 4. That is, the surface roughness may be adjusted by peeling off the surface of the remaining refractory 5 using a hammer, an ice axe, or the like (neither of which are shown). Alternatively, the surface roughness may be adjusted by grinding the surface of the remaining refractory 5 using a machine such as a heavy machine or a hydraulic drafter (neither of which are shown). In this manner, an interface 6 having a roughened surface of the remaining refractory 5 is formed, as shown in FIG. 1C . Note that it is not necessary to perform a roughness adjustment step of adjusting the surface roughness of the remaining refractory 5 after the removal step of removing the surface deposit 4. It is preferable to adjust the surface roughness of the remaining refractory 5 while removing the surface deposit 4. That is, it is preferable to perform the removal step and the roughness adjustment step described above almost simultaneously. Furthermore, if the standard deviation of the surface roughness of the remaining refractory 5 is equal to or greater than a predetermined threshold value after the surface deposit 4 is removed and the remaining refractory 5 is exposed, there is no need to perform surface roughness adjustment thereafter.

[0027] (Water application process) Further, the interface 6 formed as described above is applied with 0.010 g / cm 2 More than 0.250g / cm 2It is preferable to apply water as follows: When the interface 6 is in a dry state, specifically, the amount of water applied to the interface 6 is 0.010 g / cm 2 If the water content of the newly added monolithic material is less than 0.250 g / cm, the moisture in the newly added monolithic material will be absorbed by the remaining refractory 5. As a result, the monolithic material with reduced moisture content and the remaining refractory 5 cannot be sufficiently bonded together, and the bonding interface therebetween may become a weak part with reduced adhesive strength, and this is to be avoided. 2 If the water content is more than 0.010 g / cm, there will be an excess of water at the joint interface. In other words, there is a possibility that the amount of water relative to the binder in the newly added amorphous material will be excessive, causing the joint interface to become a weak part with reduced adhesive strength, and this is to be avoided. Therefore, when moisture is applied to the interface 6, which is the joining surface of the amorphous material to be added, the amount of water to be applied should be 0.010 g / cm. 2 More than 0.250g / cm 2 It is preferable that the content is within the following range.

[0028] Water may be applied to the interface 6 using, for example, a watering device with a spray nozzle capable of controlling the water flow rate, or a spray bottle capable of spraying water in a mist-like manner. After water is applied to the interface 6, it is preferable to add new amorphous material within two hours at the latest after the application of water so that the interface 6 does not dry out. It is more preferable to add new amorphous material within one hour after the application of water. Furthermore, it is preferable that the environment surrounding the container in which new amorphous material is added and applied has a temperature of 0°C or higher and 40°C or lower, and a humidity of 30% RH or higher and 100% RH or lower. This is to prevent evaporation of the water attached to the surface of the amorphous material.

[0029] (Construction process) Thereafter, new monolithic material is applied to the interface 6. It is preferable that the new monolithic material be made of substantially the same material as the remaining refractory 5, and the monolithic material is added and applied until the thickness of the work refractory layer 3 reaches the thickness determined by design, i.e., the original thickness. Figure 1 (D) shows the state in which the monolithic material has been added and applied until the original thickness is reached. The application method may be a conventionally known application method.

[0030] (Method for determining the standard deviation of surface roughness) A method for determining the threshold value of the standard deviation of surface roughness in the roughness adjustment process will be described. The adhesive strength of amorphous materials varies depending on the type of material used, i.e., its chemical composition. Therefore, the inventors conducted extensive testing and found that the adhesive strength varies depending on the graphite content of the amorphous material. Furthermore, it was found that if the adhesive strength is 50% or more of the bending strength of the workpiece refractory layer 3, i.e., half or more of the strength of the original workpiece refractory layer 3, the durability of the container to which the new amorphous material has been added can be ensured and the adhesive strength is sufficient.

[0031] As will be described in detail in the examples below, it has been found that the larger the standard deviation of the surface roughness of the interface 6, the higher the above-mentioned ratio, i.e., the adhesive strength. It has also been found that the higher the graphite content in the monolithic material, the higher the adhesive strength even if the standard deviation of the surface roughness is small. Specifically, when the graphite content of the monolithic material is 5 mass %, it has been found that by setting the standard deviation of the surface roughness to 500 μm or more, the adhesive strength becomes 50% or more of the bending strength of the original workpiece refractory layer 3.

[0032] From the above, when the amorphous material contains graphite, it is preferable to adjust the surface roughness of the extension surface based on the graphite content, and to adjust the surface roughness of the extension surface, interface 6, so that the standard deviation of the surface roughness is 500 μm or more.

[0033] When determining the threshold value of the standard deviation of surface roughness, it is preferable to prepare a table that associates the material that makes up the irregular material with the standard deviation of surface roughness at which the adhesive strength of the irregular material is 50% or more. The table is used to set the target standard deviation of surface roughness for the irregular material to be processed. Then, the target value of the standard deviation of surface roughness is used as the threshold value to adjust the standard deviation of surface roughness.

[0034] Therefore, according to the method for adding monolithic material according to this embodiment, when new monolithic material is added, the new monolithic material can be sufficiently bonded to the remaining refractory material 5, which is the base material. Furthermore, the surface roughness of the remaining refractory material 5 is adjusted while removing the surface deposits 4. Therefore, compared to the methods described in Patent Documents 1 and 2, in which a coating material is applied to the interface and then the monolithic refractory is poured in, and the method described in Patent Document 3, in which monolithic refractory is inserted into multiple holes drilled at the interface and then the monolithic refractory is poured in, the method for adding monolithic material according to this embodiment is easier to install because it does not require the steps of applying a coating material or inserting the monolithic refractory. As a result, the installation efficiency when adding monolithic material to the above-mentioned container can be improved, and material costs and installation costs (repair costs) can be reduced.

[0035] In the method for adding and constructing an amorphous material according to this embodiment, a graphite-containing amorphous refractory has been described as an example of the amorphous material, but the invention is not limited thereto. For example, examples of amorphous materials that can be used in the method for adding and constructing an amorphous material according to this embodiment include various amorphous refractories having chemical compositions such as alumina, alumina-silica, magnesia, dolomite, spinel, alumina-spinel, alumina-magnesia, alumina-spinel-magnesia, magnesia-carbon, alumina-magnesia-carbon, alumina-spinel-carbon, alumina-silicon carbide-carbon, and alumina-roseki-silicon carbide-carbon.

[0036] Furthermore, the monolithic material is not limited to monolithic refractories, and may be, for example, concrete, cement, etc. In the case of concrete or cement, the present application can be applied when the pouring area is divided into multiple blocks, and concrete that has been poured and hardened in advance, new concrete on top of the cement, and cement are poured in sequence. In the case of concrete or cement, an altered layer is rarely formed on the surface, so there is no need to remove the altered layer. [Example]

[0037] Next, an example of the method for extending monolithic refractories according to this embodiment will be described. In this example, three types of monolithic refractory test pieces with different graphite contents, manufactured in accordance with JIS R 2553 "Testing Method for Strength of Castable Refractories," were used as the monolithic materials. Specifically, three types of test pieces with different graphite contents were prepared: alumina-magnesia, alumina-spinel-3% graphite by mass, and alumina-spinel-5% graphite by mass. The alumina-magnesia test piece had a graphite content of 0% by mass, the alumina-spinel-3% graphite by mass test piece had a graphite content of 3% by mass, and the alumina-spinel-5% graphite by mass test piece had a graphite content of 5% by mass. The test pieces measured 40 mm × 40 mm × 160 mm. The effect of the standard deviation of the surface roughness of the extension surface (interface 6) on the adhesive strength of each test piece was then investigated.

[0038] (Comparative Example 1) Each test piece was cut at the center in the longitudinal direction of the test piece with a small diamond cutter to form a smooth cut surface. Two divided pieces were obtained for each test piece. The moisture content of the smooth cut surface of one of the two divided pieces was 0.010 g / cm. 2 More than 0.250g / cm 2Water was applied so that the thickness was within the range shown below. The divided pieces were then positioned on one side of a formwork with inner dimensions of 40 mm × 40 mm × 160 mm, with the cut surface positioned toward the center of the formwork in the longitudinal direction. A new castable refractory material of the same material as the test pieces was mixed and poured into the space on the other side of the formwork in the longitudinal direction, and then added to the divided pieces. The test pieces were then cured at room temperature for 24 hours, removed from the formwork, and dried at 110°C for 24 hours. A coking firing treatment was also performed at 1150°C, the estimated temperature of the added surface during actual furnace use. A three-point bending strength test was then performed on each divided piece to which the newly added castable refractory material had been added, and the ratio of the adhesive strength (adhesive strength / bending strength) to the bending strength of a test piece that had not been subjected to such processing (bending strength of the original test piece) was calculated. The three points labeled "cut surface" in Figure 3 represent the test results for each test piece in Comparative Example 1. The symbol "●" indicates alumina-magnesia, the symbol "◆" indicates alumina-spinel-3% graphite by mass, and the symbol "▲" indicates alumina-spinel-5% graphite by mass.

[0039] (Comparative Example 2) Each test piece was divided into two by a three-point support bending test, and a fracture surface was formed on each. Water was applied to the fracture surfaces in the same manner as in Comparative Example 1, and slag with the chemical composition shown in Table 1 was placed on top, followed by slag infiltration treatment at 1600°C for two hours. The ratio was then calculated in the same manner as in Comparative Example 1. In Figure 3, the three points marked "with slag infiltration layer" represent the test results for each test piece in Comparative Example 2.

[0040] [Table 1]

[0041] (Example 1) Each test piece was divided into two by a three-point support bending test to form a fracture surface. Otherwise, the ratio was calculated in the same manner as in Comparative Example 1. The three points marked as fracture surface in Figure 3 show the test results for each test piece in Invention Example 1.

[0042] (Example 2) Each test specimen was divided into two by a three-point support bending test, and fracture surfaces were formed on each. Water was applied to the fracture surfaces as in Comparative Example 1, and slag was placed on each fracture surface of each test specimen as in Comparative Example 2, for slag infiltration treatment. The slag was then removed using a hammer, ice axe, electric sander, etc., and the surface of the test specimen exposed by the slag removal was ground to form irregularities. The ratio was then calculated as in Comparative Example 1. In Figure 3, the three points marked "slag infiltration layer removed" show the test results for each test specimen in Example 2.

[0043] Figure 3 shows the relationship between the standard deviation of the surface roughness of the remaining refractory and the proportion of adhesive strength in the bending strength of the workpiece refractory layer. As shown in Figure 3, for all three types of test pieces with different graphite contents, the higher the standard deviation of the surface roughness, the higher the adhesive strength after the extension work.

[0044] However, in Comparative Example 2, in which new monolithic refractory was added to the existing slag-infiltrated layer, the adhesive strength did not even reach 20% of the original strength of the monolithic refractory, and was found to be significantly lower than in Invention Example 1, which had roughly the same standard deviation of surface roughness.On the other hand, in Invention Example 2, the adhesive strength was found to exceed 60% of the original strength of the monolithic refractory.

[0045] Furthermore, as shown in Figure 3, it was found that the standard deviation of the surface roughness at which the adhesive strength is 50% or more of the original strength of the monolithic refractory varies depending on the graphite content. That is, in Inventive Examples 1 and 2, and Comparative Example 2, the higher the graphite content, the lower the standard deviation of the surface roughness at which the adhesive strength is 50% or more of the original strength of the monolithic refractory. These results indicate that the presence or absence of a slag-impregnated layer has a much greater effect on adhesive strength after the extension of the monolithic refractory than the standard deviation of the surface roughness, and that removing the slag-impregnated layer improves adhesive strength. Furthermore, when there is no slag-impregnated layer or when the slag-impregnated layer is removed, as in Inventive Examples 1 and 2, the adhesive strength can be improved to 50% or more of the original strength by setting the standard deviation of the surface roughness of interface 6 to 500 μm or more. When tested on an actual machine, by making the adhesive strength of the added area more than half that of the original material (base material), the strength developed at the added interface can be used to suppress peeling that starts from the added interface. [Explanation of symbols]

[0046] 1 Ironhide 2 Permanent brick layer 3. Workpiece refractory layer 4 Surface deposits 5 Remaining refractory (work refractory layer) 6 Interface 7 Surface roughness measuring device 8 Image data acquisition unit 9. 3D model generation section 10 Calculation section 11 Judgment section 12 Output section 13 Camera

Claims

1. A method for adding irregular materials to the surface of a base material, comprising: a roughness adjusting step of adjusting the height distribution of the irregularities on the surface of the base material so that the standard deviation of the height distribution of the irregularities on the surface of the base material is 500 μm or more; and a construction step of adding and constructing a new irregular material to the surface of the base material whose unevenness height distribution on the surface of the base material has been adjusted in the roughness adjustment step, In the roughness adjustment process, a 3D model image of the surface of the base material is generated based on image data of the surface of the base material photographed by a camera, and the standard deviation of the height distribution of the unevenness on the surface of the base material is calculated as a statistical quantity of the height distribution of the unevenness on the surface of the base material based on the profile of the 3D model image.

2. The method for extending and constructing irregular materials as described in claim 1, wherein the roughness adjustment process adjusts the height distribution of the unevenness on the surface of the base material while removing surface deposits on the surface of the base material before extending and constructing the irregular material, or adjusts the height distribution of the unevenness on the surface of the base material after removing surface deposits on the surface of the base material before extending and constructing the irregular material.

3. After adjusting the height distribution of the irregularities on the surface of the base material in the roughness adjusting step, a 0.010 g / cm ２ 0.250g / cm or more ２ The method for extending and constructing irregular materials according to claim 1 or 2, further comprising a water application step of applying water as follows:

4. A method for extending and constructing irregular materials as described in claim 1 or 2, wherein the adhesive strength between the new irregular material and the surface of the base material after adjusting the height distribution of the unevenness on the surface of the base material in the roughness adjustment process is at least 50% or more of the bending strength of the base material.

5. 3. The method for extending and constructing an unshaped material according to claim 1, wherein the unshaped material is a graphite-containing unshaped refractory material containing graphite.

6. The method for extending and constructing amorphous materials according to claim 5, wherein the roughness adjustment process adjusts the height distribution of the irregularities on the surface of the base material based on the graphite content of the graphite-containing amorphous refractory material.

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