Fired Refractory Product with MA-Spinel Matrix
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Solution Overview
Problem
Refractory ceramic products face challenges in achieving high-temperature resistance (> 1,500°C) while maintaining good thermal shock resistance, cold compressive strength, and low gas permeability, especially in applications with varying atmospheres.
Innovation Solution
A fired refractory product is developed with a structure comprising coarse MgO particles and a matrix based on MA-spinel, where the MA-spinel is formed in-situ during firing, creating gap-like pores that enhance thermal shock resistance and ductility, and minimizing free MgO content to prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high temperature resistance (>1500°C) is achieved through conventional refractory materials, then temperature resistance is improved, but thermal shock resistance and cold compressive strength deteriorate
Solution Approach 1:
The patent employs a composite microstructure consisting of coarse MgO particles (30-500 μm) embedded in a fine-grained MA-spinel matrix. This composite structure combines the high-temperature stability of MgO with the mechanical strength and thermal shock resistance of the spinel matrix, achieving both high temperature resistance (>1500°C) and improved cold compressive strength (>50 MPa).
Solution Approach 2:
The patent creates local heterogeneity in the microstructure by distributing coarse MgO particles throughout the fine-grained spinel matrix. The coarse particles provide thermal stability while the fine matrix provides mechanical strength and ductility. This local quality differentiation allows the material to simultaneously achieve high temperature resistance and improved mechanical properties.
2Temperature
If high temperature resistance (>1500°C) is achieved through conventional refractory materials, then temperature resistance is improved, but thermal shock resistance deteriorates
Solution Approach 1:
The composite microstructure of coarse MgO particles in a fine-grained MA-spinel matrix provides both high-temperature stability and excellent thermal shock resistance. The spinel matrix acts as a thermally responsive phase that can accommodate rapid temperature changes, while the coarse MgO particles maintain structural integrity at elevated temperatures.
Solution Approach 2:
The patent optimizes the grain size parameters, using coarse MgO particles (30-500 μm) combined with a fine-grained spinel matrix. This parameter optimization creates a microstructure that can withstand thermal shock while maintaining high-temperature resistance, achieving thermal shock resistance without sacrificing temperature resistance.
3Temperature
If high temperature resistance (>1500°C) is achieved through conventional refractory materials, then temperature resistance is improved, but gas permeability increases
Solution Approach 1:
The composite microstructure with coarse MgO particles embedded in a fine-grained spinel matrix creates a dense, low-permeability structure. The spinel matrix fills the interstices between coarse particles, creating a continuous fine-grained phase that effectively blocks gas penetration while maintaining high-temperature resistance.
4Ease of manufacture
If refractory ceramic products are made more ductile to reduce brittleness, then ease of manufacture is improved, but temperature resistance may deteriorate
Solution Approach 1:
The composite microstructure achieves ductility through the fine-grained spinel matrix while maintaining high-temperature resistance through the coarse MgO particles. The spinel matrix provides the ductile, less brittle characteristics needed for ease of manufacture, while the MgO particles ensure temperature resistance up to >1500°C.
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
The product achieves improved thermal shock resistance, high cold compressive strength, and low gas permeability, making it suitable for high-temperature applications in both reducing and oxidizing atmospheres, with enhanced processing ease and reduced brittleness.
Implementation Method 1
a matrix based on MA-spinel, where the MA-spinel is formed in-situ during firing
Implementation Method 2
heating them at least to temperatures at which the batch components sinter
Implementation Method 3
heating them at least to temperatures at which the batch components sinter
Implementation Method 4
gap-like pores that enhance thermal shock resistance
Data Source
Figure 1~1a
AI summary
The invention relates to a baked refractory ceramic product. According to the invention, both shaped and unshaped products come within this generic term. Shaped products are those which have a defined shape, so that they can be ready-made at the manufacturer's premises. The shaped products include: bricks, nozzles, tubes, stoppers, plates, etc. The products categorized as unshaped products include those which are usually produced at the user's premises from a suitable material. These include bottoms of furnace assemblies which are cast from a material, but also repair materials, etc.