Aluminum-Containing Refractory for Steel Casting
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Solution Overview
Problem
Conventional refractory materials for steel casting, particularly those containing metal aluminum, face challenges in maintaining thermal shock resistance while avoiding destruction due to volume expansion and excessive densification, which compromises corrosion and erosion resistance.
Innovation Solution
The refractory material is designed with a specific range of 1 to 15% metal aluminum content to control void volume within the refractory organization, allowing for controlled expansion and densification, thereby enhancing oxidation resistance and thermal shock resistance without compromising other properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of metal aluminum is added to enhance corrosion and erosion resistance, then oxidation resistance and strength are improved, but volume expansion and excessive densification occur causing thermal shock resistance to deteriorate
Solution Approach 1:
The invention optimizes the metal aluminum content parameter within a specific range (1-15% by mass) to achieve the best balance between corrosion resistance and thermal shock resistance. This parameter optimization prevents excessive densification while maintaining adequate protective properties.
Solution Approach 2:
The invention creates a composite refractory material combining metal aluminum with other refractory components (such as carbon, silicon carbide, and fireclay) to achieve synergistic effects. The composite structure allows the metal aluminum to provide corrosion protection while the other components maintain thermal shock resistance.
2Reliability
If metal aluminum content is increased to improve oxidation resistance, then corrosion resistance is enhanced, but refractory organization is destructed due to volume expansion
Solution Approach 1:
The invention precisely controls the metal aluminum content parameter within 1-15% by mass to prevent excessive volume expansion that would destruct the refractory organization. This optimized parameter range ensures adequate oxidation resistance without compromising structural integrity.
Solution Approach 2:
The invention anticipates the volume expansion issue by pre-designing the refractory matrix structure to accommodate the expected expansion from metal aluminum reactions. The matrix is formulated to cushion and absorb the expansion stress, preventing organization destruction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively suppresses refractory destruction, enhances thermal shock resistance, and maintains or improves corrosion and erosion resistance, allowing for optimized performance in steel casting applications.
Implementation Method 1
the strength, the oxidation resistance, the corrosion and erosion resistances
Implementation Method 2
a volume increase by the reactions which take place upon a heat receiving of the metal aluminum
Implementation Method 3
the thermal shock resistance, the abrasion resistance, the corrosion and erosion resistances
Data Source
AI summary
The problem of the present invention is to suppress destruction of a refractory which contains a metal aluminum. The refractory of the present invention is characterized by that the refractory is a refractory for steel casting which includes a refractory material containing a free carbon in the range of 1 to 10% by mass, both inclusive, a metal aluminum in the range of 1 to 15% by mass, both inclusive, and a metal oxide in a balance; and the refractory for steel casting satisfies Equation 1, provided that a metal aluminum content in the refractory is designated by Al% by mass, an apparent porosity thereof is designated by P%, and a bulk density thereof is designated by D. 0.31×A1≤P−4/D