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Calcium zirconate–based refractory with improved thermal shock damage resistance from Egyptian dolomite and zirconia through in situ spinel synthesis

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Abstract

Locally found Egyptian dolomite, commercial zirconia, and alumina were used to fabricate calcium zirconate-based refractory with improved thermal shock damage resistance. CaZrO3/MgO (CZM) and CaZrO3/MgAl2O4 (CZS) green compacts were obtained by mixing dolomite, commercial zirconia, and alumina with molar ratios of 1:1.23:0 and 1:1.23:0.59, respectively, and then ball milled for 1 h and uniaxially pressed at 150 MPa. The obtained green compacts were sintered at 1200, 1300, 1500, and 1650 °C for 2 h with a heating rate of 5 °C/min. The phase composition, microstructure, densification parameters, and thermal shock damage resistance of the prepared refractory were investigated. The results showed that CaZrO3 was present as the predominant phase and c-ZrO2 as a secondary phase due to the solubility of calcium and magnesium ions in the zirconia lattice structure. CZM1500 and CZS1500 showed a bulk density of 4.05 and 3.8 g/cm3 respectively. Thermal shock damage resistance of CZM samples was greatly improved with the in situ spinel synthesis where CZS1500 was able to withstand 16 cycles before fracturing compared to 10 cycles recorded for CZM1500.

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Funding

This work was supported by the National Foreign Experts Project of the Ministry of Science and Technology (Grant number QN2021041002L).

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Authors and Affiliations

  1. School of Materials Science and Engineering, Xi’an University of Technology, Xi’an, 710048, China

    Mahmoud Abdelgawad, Shufeng Li & Xin Zhang

  2. Refractory and Ceramic Materials Department, Central Metallurgical R. & D. Institute, Cairo, Egypt

    Mahmoud Abdelgawad, Ahmed A. M. El-Amir & Emad M. M. Ewais

  3. Xi’an Key Laboratory of Advanced Powder Metallurgy Materials and New Technology, Xi’an University of Technology, Xi’an, 710048, China

    Shufeng Li & Xin Zhang

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  1. Mahmoud Abdelgawad
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  2. Shufeng Li
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  4. Xin Zhang
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  5. Emad M. M. Ewais
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Correspondence to Mahmoud Abdelgawad or Shufeng Li.

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Abdelgawad, M., Li, S., El-Amir, A.A.M. et al. Calcium zirconate–based refractory with improved thermal shock damage resistance from Egyptian dolomite and zirconia through in situ spinel synthesis. J Aust Ceram Soc 60, 485–495 (2024). https://doi.org/10.1007/s41779-023-00937-0

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