Refractory Ceramic Product Microstructure Design
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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, flexibility, high cold compressive strength, and low gas permeability, which are critical for applications like glass melting tanks and metallurgical processes.
Innovation Solution
A fired refractory ceramic product with a specific microstructure comprising a finely divided matrix and coarse particles, where the distance between coarse particles corresponds to 0.7 to 3 times their maximum diameter, and a proportion of fine grain being 50 to 90% by mass and coarse grain 10 to 50% by mass, ensuring low gas permeability and high structural elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If refractory ceramic products are designed for high-temperature resistance (>1,500°C), then temperature resistance is improved, but thermal shock resistance and flexibility deteriorate
Solution Approach 1:
The patent applies local quality by creating distinct regions within the refractory ceramic product: a dense shell layer (10-40 mass%) with specific grain size distribution for high-temperature resistance, and a porous core layer (60-90 mass%) with controlled porosity (20-40%) for thermal shock resistance. This spatial differentiation allows simultaneous optimization of both temperature resistance and thermal shock resistance.
Solution Approach 2:
The patent employs composite materials by combining refractory ceramic materials with different properties in a layered structure. The dense shell uses materials with high melting points for temperature resistance, while the porous core uses materials with better thermal shock resistance, creating a composite structure that achieves both required properties simultaneously.
2Object-affected harmful factors
If refractory ceramic products are made dense to reduce gas permeability, then gas permeability is reduced, but thermal shock resistance and flexibility worsen
Solution Approach 1:
The patent applies local quality by creating distinct regions within the refractory ceramic product: a dense shell layer (10-40 mass%) with specific grain size distribution for high-temperature resistance, and a porous core layer (60-90 mass%) with controlled porosity (20-40%) for thermal shock resistance. This spatial differentiation allows simultaneous optimization of both temperature resistance and thermal shock resistance.
Solution Approach 2:
The patent utilizes porous materials in the core layer (60-90 mass%) with controlled porosity of 20-40%. This porous structure improves thermal shock resistance and flexibility while the dense shell layer (10-40 mass%) maintains low gas permeability, thus resolving the contradiction between gas permeability reduction and thermal shock resistance maintenance.
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 exhibits excellent thermal shock resistance, high cold compressive strength, low gas permeability, and improved flexibility, as demonstrated by wedge splitting tests and microstructural analysis, with properties such as hot bending strength > 10MPa and cold compressive strength > 50MPa, and gas permeability < 1•10^-13 m², suitable for extreme temperature applications.
Implementation Method 1
heating them at least to temperatures at which the batch components sinter
Data Source
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AI summary
The invention relates to a fired refractory ceramic product. According to the invention, this generic term encompasses both shaped and unshaped products. Shaped products are ones which have a defined shape so that they can be manufactured in finished form on the premises of the manufacturer. Shaped products include: bricks, nozzles, tubes, stoppers, plates, etc. The term unshaped products includes ones which are usually produced by the user from a corresponding composition. They include bases for furnaces which are cast from a composition but also repair compositions, etc.