Porous Refractory Cast Material for Molten Metal Inclusion Control

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Solution Overview

Problem

Existing refractory materials used in metallurgical vessels are ineffective in preventing the formation and retention of endogenous inclusions in molten metals, leading to defects in the final metal products due to high reactivity and oxidation.

Innovation Solution

A refractory material with configured porosity, comprising a closed refractory aggregate fraction and a binder system, designed to withstand high temperatures and chemical reactivity, featuring open, continuous, and tortuous pores to retain and direct molten metal while minimizing oxidation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional refractory materials are used in metallurgical vessels, then the vessels can withstand high temperatures, but they fail to prevent formation and retention of endogenous inclusions in molten metals

Engineering Contradiction:

Improveeffectiveness in preventing inclusion formationVSAvoidendogenous inclusions

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies porous refractory materials with specifically configured pore structures (open, continuous, tortuous pores) to create a physical barrier that retains molten metal and prevents oxidation. The porous structure allows the refractory material to interact with the molten metal while maintaining thermal resistance and chemical stability, thereby reducing inclusion formation without compromising temperature withstand capability

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent uses composite refractory materials combining multiple components (aggregates, binders, and porous structures) to achieve both thermal resistance and inclusion prevention. The composite structure integrates the heat-resistant properties of traditional refractories with the inclusion-retaining capabilities of porous materials, creating a multi-functional material that addresses both high temperature operation and oxidation prevention

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If porous structures are introduced to retain molten metal and reduce inclusions, then oxidation is minimized, but the material must withstand high temperatures and chemical reactivity

Engineering Contradiction:

ImproveoxidationVSAvoidhigh temperature resistance

Core Design Contradiction:

Object-affected harmful factorsVSTemperature

Solution Approach 1:

The patent employs porous refractory materials with controlled pore sizes and distributions that create physical barriers against oxidation while maintaining thermal stability. The porous structure prevents direct contact between molten metal and atmospheric oxygen, reducing oxidation without compromising the material's ability to withstand high temperatures through the inherent thermal resistance of the porous refractory matrix

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent modifies the physical and chemical parameters of refractory materials by controlling pore size, porosity level, and material composition to optimize both oxidation resistance and thermal stability. By adjusting these parameters, the material achieves effective oxidation prevention while maintaining the high temperature resistance required for metallurgical vessel operation

Inventive Principle:

Principle #35Parameter changes

3Productivity

If refractory materials with configured porosity are used, then inclusions are reduced and metal transfer is enhanced, but the material structure becomes more complex

Engineering Contradiction:

Improvemetal transfer efficiencyVSAvoidmaterial structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent uses porous refractory materials with naturally formed pore structures that enhance metal transfer efficiency through improved fluid flow characteristics. The porous structure facilitates better thermal contact and chemical interaction with molten metal, enhancing productivity while the pores are formed through controlled material composition rather than complex external structuring

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent optimizes material parameters such as aggregate size distribution, binder type, and porosity level to achieve enhanced metal transfer efficiency. By adjusting these parameters during material formulation, the patent improves productivity without requiring complex structural designs, as the enhancements arise from optimized material properties rather than complex geometry

Inventive Principle:

Principle #35Parameter changes

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 material effectively reduces the formation and retention of inclusions, enhances metal transfer processes, and minimizes oxidation, providing improved quality and efficiency in metallurgical operations.

Implementation Method 1

Methodology Applied

Scientific EffectPorosity: Porosity

Data Source

PatentUS12410106B2Porous refractory cast material, its use and production

Publication Date: 2025.09.09 VESUVIUS USA CORP

AI summary

A porous refractory cast material contains a closed refractory aggregate fraction having a minimum particle size and a maximum particle size; the ratio of maximum particle size to minimum particle size is 10:1 or less. This closed refractory aggregate fraction comprises all of the porous refractory cast material having a particle diameter greater than 0.1 mm. The porous refractory cast material also contains a binder phase containing refractory selected from calcium aluminate cement, alumina phosphate, hydratable alumina, colloidal silica and combinations thereof. Also disclosed is a metallurgical vessel with an interior lining incorporating the porous refractory cast material.