Impact on aggregate/matrix bonding when a refractory contains zinc aluminate instead of spinel and magnesia-chrome

Somnath Mandal; James G. Hemrick; Manoj K. Mahapatra

doi:10.1111/jace.19214

Impact on aggregate/matrix bonding when a refractory contains zinc aluminate instead of spinel and magnesia-chrome

Somnath Mandal, James G. Hemrick, Manoj K. Mahapatra

Mechanical Properties and Mechanics

Research output: Contribution to journal › Article › peer-review

8 Scopus citations

Abstract

The high hot strength of MgO–Cr₂O₃ refractory is often ascribed to its intimate aggregate/matrix bonding. For a fundamental comparison with it, ∼2 mm aggregates of MgO and Al₂O₃ were separately embedded in ZnAl₂O₄ and MgAl₂O₄ matrices, sintered at 1600°C, and examined. It was found that similarity of thermal expansion coefficient (TEC) between the aggregate and the matrix is critical to achieve good bonding and this is more important than the extent of interdiffusion. The TEC mismatch of ≥5.7 × 10⁻⁶ K⁻¹ caused significant undesirable debonding in MgO aggregate/MgAl₂O₄ matrix sample and MgO/ZnAl₂O₄ despite >736 μm Zn²⁺ diffusion depth in the latter. Direct bonding, as inferred from a thicker interfacial reaction layer and a greater shift of the aggregate/matrix interface before and after firing, was better in MgAl₂O₄/ZnAl₂O₄ combination, followed by tabular Al₂O₃/ZnAl₂O₄ and Al₂O₃/MgAl₂O₄. Powder X-ray diffraction indicated that the volatilization of ZnAl₂O₄ at 1600°C in air was negligible compared to MgO–Cr₂O₃.

Original language	English
Pages (from-to)	5662-5678
Number of pages	17
Journal	Journal of the American Ceramic Society
Volume	106
Issue number	10
DOIs	https://doi.org/10.1111/jace.19214
State	Published - Oct 2023

Funding

The US Department of Energy (Advanced Manufacturing Office, AMO) funded this work (grant number: DE-EE0001761). The authors are grateful to Mr. Glenn McIntyre (HarbisonWalker International), Dr. Andus Buhr and Dr. Mark Snyder (Almatis), Mr. Timothy McGrady and Ms. Veronica Vasquez (U.S. Zinc) for generous donation of raw materials with accompanying certificate of analysis. Technical suggestions received from Dr. Haibin Ning (University of Alabama at Birmingham), Dr. Kaberi Das (Government College of Engineering and Ceramic Technology, India), Dr. Dileep Kumar CJ (Saint Gobain Research India), and Mr. Santanu Mondal (Virginia Tech) had improved this paper. The authors also appreciate extensive reviews of the manuscript by Oak Ridge National Laboratory staff. This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). The US Department of Energy (Advanced Manufacturing Office, AMO) funded this work (grant number: DE‐EE0001761). The authors are grateful to Mr. Glenn McIntyre (HarbisonWalker International), Dr. Andus Buhr and Dr. Mark Snyder (Almatis), Mr. Timothy McGrady and Ms. Veronica Vasquez (U.S. Zinc) for generous donation of raw materials with accompanying certificate of analysis. Technical suggestions received from Dr. Haibin Ning (University of Alabama at Birmingham), Dr. Kaberi Das (Government College of Engineering and Ceramic Technology, India), Dr. Dileep Kumar CJ (Saint Gobain Research India), and Mr. Santanu Mondal (Virginia Tech) had improved this paper. The authors also appreciate extensive reviews of the manuscript by Oak Ridge National Laboratory staff. This manuscript has been authored by UT‐Battelle, LLC, under contract DE‐AC05‐00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid‐up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe‐public‐access‐plan).

Keywords

MgO
diffusion
refractories
spinels
zinc aluminate

Access to Document

10.1111/jace.19214

Cite this

@article{b9a4aeaf1ffd42b7921f8321340b81c3,

title = "Impact on aggregate/matrix bonding when a refractory contains zinc aluminate instead of spinel and magnesia-chrome",

abstract = "The high hot strength of MgO–Cr2O3 refractory is often ascribed to its intimate aggregate/matrix bonding. For a fundamental comparison with it, ∼2 mm aggregates of MgO and Al2O3 were separately embedded in ZnAl2O4 and MgAl2O4 matrices, sintered at 1600°C, and examined. It was found that similarity of thermal expansion coefficient (TEC) between the aggregate and the matrix is critical to achieve good bonding and this is more important than the extent of interdiffusion. The TEC mismatch of ≥5.7 × 10−6 K−1 caused significant undesirable debonding in MgO aggregate/MgAl2O4 matrix sample and MgO/ZnAl2O4 despite >736 μm Zn2+ diffusion depth in the latter. Direct bonding, as inferred from a thicker interfacial reaction layer and a greater shift of the aggregate/matrix interface before and after firing, was better in MgAl2O4/ZnAl2O4 combination, followed by tabular Al2O3/ZnAl2O4 and Al2O3/MgAl2O4. Powder X-ray diffraction indicated that the volatilization of ZnAl2O4 at 1600°C in air was negligible compared to MgO–Cr2O3.",

keywords = "MgO, diffusion, refractories, spinels, zinc aluminate",

author = "Somnath Mandal and Hemrick, \{James G.\} and Mahapatra, \{Manoj K.\}",

note = "Publisher Copyright: {\textcopyright} 2023 The American Ceramic Society.",

year = "2023",

month = oct,

doi = "10.1111/jace.19214",

language = "English",

volume = "106",

pages = "5662--5678",

journal = "Journal of the American Ceramic Society",

issn = "0002-7820",

publisher = "wiley",

number = "10",

}

TY - JOUR

T1 - Impact on aggregate/matrix bonding when a refractory contains zinc aluminate instead of spinel and magnesia-chrome

AU - Mandal, Somnath

AU - Hemrick, James G.

AU - Mahapatra, Manoj K.

PY - 2023/10

Y1 - 2023/10

N2 - The high hot strength of MgO–Cr2O3 refractory is often ascribed to its intimate aggregate/matrix bonding. For a fundamental comparison with it, ∼2 mm aggregates of MgO and Al2O3 were separately embedded in ZnAl2O4 and MgAl2O4 matrices, sintered at 1600°C, and examined. It was found that similarity of thermal expansion coefficient (TEC) between the aggregate and the matrix is critical to achieve good bonding and this is more important than the extent of interdiffusion. The TEC mismatch of ≥5.7 × 10−6 K−1 caused significant undesirable debonding in MgO aggregate/MgAl2O4 matrix sample and MgO/ZnAl2O4 despite >736 μm Zn2+ diffusion depth in the latter. Direct bonding, as inferred from a thicker interfacial reaction layer and a greater shift of the aggregate/matrix interface before and after firing, was better in MgAl2O4/ZnAl2O4 combination, followed by tabular Al2O3/ZnAl2O4 and Al2O3/MgAl2O4. Powder X-ray diffraction indicated that the volatilization of ZnAl2O4 at 1600°C in air was negligible compared to MgO–Cr2O3.

AB - The high hot strength of MgO–Cr2O3 refractory is often ascribed to its intimate aggregate/matrix bonding. For a fundamental comparison with it, ∼2 mm aggregates of MgO and Al2O3 were separately embedded in ZnAl2O4 and MgAl2O4 matrices, sintered at 1600°C, and examined. It was found that similarity of thermal expansion coefficient (TEC) between the aggregate and the matrix is critical to achieve good bonding and this is more important than the extent of interdiffusion. The TEC mismatch of ≥5.7 × 10−6 K−1 caused significant undesirable debonding in MgO aggregate/MgAl2O4 matrix sample and MgO/ZnAl2O4 despite >736 μm Zn2+ diffusion depth in the latter. Direct bonding, as inferred from a thicker interfacial reaction layer and a greater shift of the aggregate/matrix interface before and after firing, was better in MgAl2O4/ZnAl2O4 combination, followed by tabular Al2O3/ZnAl2O4 and Al2O3/MgAl2O4. Powder X-ray diffraction indicated that the volatilization of ZnAl2O4 at 1600°C in air was negligible compared to MgO–Cr2O3.

KW - MgO

KW - diffusion

KW - refractories

KW - spinels

KW - zinc aluminate

UR - http://www.scopus.com/inward/record.url?scp=85161601160&partnerID=8YFLogxK

U2 - 10.1111/jace.19214

DO - 10.1111/jace.19214

M3 - Article

AN - SCOPUS:85161601160

SN - 0002-7820

VL - 106

SP - 5662

EP - 5678

JO - Journal of the American Ceramic Society

JF - Journal of the American Ceramic Society

IS - 10

ER -

Impact on aggregate/matrix bonding when a refractory contains zinc aluminate instead of spinel and magnesia-chrome

Abstract

Funding

Keywords

Access to Document

Other files and links

Fingerprint

Cite this