Synthesis of CA₆/AlON composite with enhanced slag resistance

Abstract

Different amounts of AlON have been introduced in calcium hexaaluminate (CA₆) using two approaches, that is, one-step and two-step methods, to improve the slag resistance of CA₆. A one-step method can directly sinter the mixtures combining Al₂O₃, CaCO₃, and Al in flowing nitrogen, in which AlON clusters are always formed because of the poor wettability of Al by Al₂O₃, leading to the high porosity of CA₆/AlON composite. In a two-step method, CA₆ and AlON are prepared separately and then mixed and sintered in flowing nitrogen. Compared with the sample prepared by the one-step method, CA₆ and AlON in composite by the two-step method are more uniformly distributed, and the optimized amount of AlON added is 10wt%. The slag corrosion and penetration test shows that the CA₆/AlON composite using the two-step method exhibits superior slag corrosion protection. The promoted effect of AlON on slag penetration and corrosion resistance is also discussed.

Keywords

CA₆/AlON composite / two-step method / wettability / slag resistance

References

[1] Chen JH, Chen HY, Mi WJ, Cao Z, Li B, Li GQ. Synthesis of CaO·2MgO8Al₂O₃ (CM₂A₈) and its slag resistance mechanism. J. Eur. Ceram. Soc., 2017, 37(4): 1799.

[2] Dong BB, Yuan B, Wang G, Chen K, Han JS, Li HX. Fabrication of porous SiC/calcium hexaluminate composites. J. Eur. Ceram. Soc., 2016, 36(16): 3889.

[3] Xu LC, Wang EH, Hou XM, Chen JH, He ZJ, Liang TX. Effect of incorporation of nitrogen on calcium hexaaluminate. J. Eur. Ceram. Soc., 2020, 40(15): 6155.

[4] Li B, Li GQ, Chen HY, Chen JH, Hou XM, Li Y. Physical and mechanical properties of hot-press sintering ternary CM₂A₈ (CaMg₂A1₁₆0₂₇) and C₂M₂A₁₄ (Ca₂Mg₂Al₂₈0₄₆)) ceramics. J. Adv. Ceram., 2018, 7(3): 229.

[5] Utsunomiya A, Tanaka K, Morikawa H, Marumo F, Kojima H. Structure refinement of CaO6Al₂O₃. J. Solid State Chem., 1988, 75(1): 197.

[6] Domínguez C, Chevalier J, Torrecillas R, Fantozzi G. Microstructure development in calcium hexaluminate. J. Eur. Ceram. Soc., 2001, 21(3): 381.

[7] Iyi N, Takekawa S, Kimura S. Crystal chemistry of hexaaluminates: β-alumina and magnetoplumbite structures. J. Solid State Chem., 1989, 83(1): 8.

[8] Chen JH, Chen HY, Yan MW, Cao Z, Mi WJ. Formation mechanism of calcium hexaluminate. Int. J. Miner. Metall. Mater., 2016, 23(10): 1225.

[9] Salomão R, Ferreira VL, de Oliveira IR, Souza ADV, Correr WR. Mechanism of pore generation in calcium hexaluminate (CA₆) ceramics formed in situ from calcined alumina and calcium carbonate aggregates. J. Eur. Ceram. Soc., 2016, 36(16): 4225.

[10] Asmi D, Low IM. Physical and mechanical characteristics of in situ alumina/calcium hexaluminate composites. J. Mater. Sci. Lett., 1998, 17(20): 1735.

[11] Vázquez BA, Pena P, de Aza AH, Sainz MA, Caballero A. Corrosion mechanism of polycrystalline corundum and calcium hexaluminate by calcium silicate slags. J. Eur. Ceram. Soc., 2009, 29(8): 1347.

[12] Xu L, Chen M, Wang N, Yin XL. Corrosion mechanism of MgAl₂O₄-CaAl₄O₇-CaAl₁₂O₁₉ composite by steel ladle slag: Effect of additives. J. Eur. Ceram. Soc., 2017, 37(7): 2737.

[13] Xu L, Yin XL, Wang N, Chen M. Effect of Y₂O₃ addition on the densification, microstructure and mechanical properties of MgAl₂O₄-CaAl₄O₇-CaAl₁₂O₁₉ composites. J. Alloys Compd., 2017, 702, 472.

[14] Feng B, Wang ZH, Fan YH, Gu JH, Zhang Y. Creep deformation behavior during densification of ZrB₂-SiBCN ceramics with ZrO₂ additive. J. Adv. Ceram., 2020, 9(5): 544.

[15] Yao SZ, Wang EH, Chen JH, Chou KC, Hou XM. Effectively controlling the crystal growth of Cr₂O₃ using SiO₂ as the second phase. J. Am. Ceram. Soc., 2019, 102(4): 2187

[16] Luo Q, Gu HZ, Fang YN, Huang A, Zhang MJ, Luo ZA. Enhancement of the densification and thermal properties of Ca₂Mg₂Al₂₈O₄₆ ceramic by MnO addition. Ceram. Int., 2020, 46(11): 18734.

[17] Xu L, Chen M, Jin LY, Yin XL, Wang N, Liu L. Effect of ZrO₂ addition on densification and mechanical properties of MgAl₂O₄-CaAl₄O₇-CaAl₁₂O₁₉ composite. J. Am. Ceram. Soc., 2015, 98(12): 4117.

[18] Shabani M, Paydar MH, Moshksar MM. Fabrication and densification enhancement of SiC-particulate-reinforced copper matrix composites prepared via the sinter-forging process. Int. J. Miner. Metall. Mater., 2014, 21(9): 934.

[19] Shen YN, Xing Y, Jiang P, et al. Corrosion resistance evaluation of highly dispersed Mg-MgAl₂O₄-ZrO₂ composite and analysis of its corrosion mechanism: A chromium-free refractory for RH refining kilns. Int. J. Miner. Metall. Mater., 2019, 26(8): 1038.

[20] Corbin ND. Aluminum oxynitride spinel: A review. J. Eur. Ceram Soc., 1989, 5(3): 143.

[21] Zhong XC, Zhao HL. High-temperature properties of oxide-nonoxide refractory composites. Refractories, 2000, 34(2): 63

[22] Hong Y, Li Y, Tong SH, Yue DD, Ma JJ. Effect of the addition of Al powder on the microstructure and phase constitution of magnesia-spinel composites sintered at 1800°C in N₂. Key Eng. Mater., 2016, 697, 345.

[23] Takeda K, Hosaka T. Characteristics of new raw material AlON for refractories. Interceram, 1989, 38(1): 18

[24] Ma CH, Li Y, Jiang P, Xue WD, Chen JH. Formation mechanism of γ-AlON and β-SiC reinforcements in a phenolic resin-bonded Al-Si-Al₂O₃ composite at 1700°C in flowing N₂. J. Mater. Sci., 2020, 55(14): 5772.

[25] Murakami K, Iwasaki A, Akatsuka Y, Komara I. One results of sliding nozzle refractories using aluminum oxynitride. Refractories, 1986, 38(336): 18

[26] Hosaka T, Kato M. A study of compositional modification of trough mixture by using aluminum oxinitride. Refractories, 1985, 37(333): 582

[27] Sun WY, Yen TS. Phase relationships in the system Ca-Al--N. Mater. Lett., 1989, 8(5): 150.

[28] Willems HX, Hendrix MMRM, Metselaar R, de With G. Thermodynamics of AlON I: Stability at lower temperatures. J. Eur. Ceram. Soc., 1992, 10(4): 327.

[29] Zhang N, Liang B, Wang XY, Kan HM, Zhu KW, Zhao XJ. The pressureless sintering and mechanical properties of AlON ceramic. Mater. Sci. Eng. A, 2011, 528(19–20): 6259.

[30] Wang Y, Xie XM, Qi JQ, et al. Two-step preparation of AlON transparent ceramics with powder synthesized by aluminothermic reduction and nitridation method. J. Mater. Res., 2014, 29(19): 2325.

[31] Su MY, Zhou YF, Wang K, Yang ZF, Cao YG, Hong MC. Highly transparent AlON sintered from powder synthesized by direct nitridation. J. Eur. Ceram. Soc., 2015, 35(4): 1173.

[32] Rodríguez-Galicia JL, de Aza AH, Rendón-Angeles JC, Pena P. The mechanism of corrosion of Mg-CaZrO₃-calcium silicate materials by cement clinker. J. Eur. Ceram. Soc., 2007, 27(1): 79.

[33] Deng ZY, Zhu MY, Zhong BJ, Dai YG. Metallurgical properties of refining slag with different basicities. J. Northeast. Univ. (Nat. Sci.), 2012, 33(4): 555

[34] Wang EH, Chen JH, Hu XJ, Chou KC, Hou XM. Evolution of aluminum hydroxides at the initial stage of aluminum nitride powder hydrolysis. Ceram. Int., 2016, 42(9): 11429.

[35] Plimpton S. Fast parallel algorithms for short-range molecular dynamics. J. Comput. Phys., 1995, 117(1): 1.

[36] Matsui M. Molecular dynamics study of the structures and bulk moduli of crystals in the system Ca-Mg-Al₂O₃-SiO₂. Phys. Chem. Miner., 1996, 23(6): 345.

[37] Jiang CH, Li KJ, Zhang JL, et al. Molecular dynamics simulation on the effect of MgO/Al₂O₃ ratio on structure and properties of blast furnace slag under different basicity conditions. Metall. Mater. Trans. B, 2019, 50(1): 367.

[38] Jones JE. On the determination of molecular fields. II. From the equation of state of a gas. Proc. Roy. Soc. A, 1924, 106(738): 463

[39] Kim NH, Fun QD, Komeya K, Meguro T. Phase reaction and sintering behavior in the pseudoternary system AlN-Y₂O₃-Al₂O₃. J. Am Ceram Soc., 2005, 79(10): 2645.

[40] Korgul P, Wilson DR, Lee WE. Microstructural analysis of corroded alumina-spinel castable refractories. J. Eur. Ceram Soc., 1997, 17(1): 77.

[41] Chen JH, Chen HY, Mi WJ, Cao Z, Li B, Liang CJ. Substitution of Ba for Ca in the structure of CaAl₁₂O₁₉. J. Am. Ceram Soc., 2017, 100(1): 413.

[42] McCauley JW, Patel P, Chen MW, et al. AlON: A brief history of its emergence and evolution. J. Eur. Ceram. Soc., 2009, 29(2): 223.

[43] Díaz LA, Torrecillas R, de Aza AH, Pena P. Effect of spinel content on slag attack resistance of high alumina refractory castables. J. Eur. Ceram. Soc., 2007, 27(16): 4623.

[44] Braulio MAL, Martinez AGT, Luz AP, Liebske C, Pandolfelli VC. Basic slag attack of spinel-containing refractory castables. Ceram. Int., 2011, 37(6): 1935.

[45] Luz AP, Braulio MAL, Martinez AGT, Pandolfelli VC. Slag attack evaluation of in situ spinel-containing refractory castables via experimental tests and thermodynamic simulations. Ceram. Int., 2012, 38(2): 1497.

[46] Guo CY, Wang EH, Hou XM, et al. Preparation of Zr⁴⁺ doped calcium hexaaluminate with improved slag penetration resistance. J. Am. Ceram. Soc., 2021, 104(9): 4854.

[47] Yan MW, Li Y, Li HY, Sun Y, Qin HX, Zheng QY. Preparation and ladle slag resistance mechanism of MgAlON bonded Al₂O₃-MgAlON-Zr₂Al₃C₄-(Al₂CO)_1−x(AlN)_x refractories. Ceram. Int., 2019, 45(1): 346.

[48] Oishi Y, Cooper AR, Kingery WD. Dissolution in ceramic systems: III, boundary layer concentration gradients. J. Am. Ceram. Soc., 1965, 48(2): 88.

[49] Park Y, Min DJ. Sulfide capacity of Ca-SiO₂-Fe-Al₂O₃-MgO_satd slag. ISIJ Int., 2016, 56(4): 520.

[50] Wang JJ, Zhang LF, Cheng G, Ren Q, Ren Y. Dynamic mass variation and multiphase interaction among steel, slag, lining refractory and nonmetallic inclusions: Laboratory experiments and mathematical prediction. Int. J. Miner. Metall. Mater., 2021, 28(8): 1298.

[51] Xu CY, Wang C, Xu RZ, Zhang JL, Jiao KX. Effect of Al₂O₃ on the viscosity of Ca-SiO₂-Al₂O₃-Mg-Cr₂O₃ slags. Int. J. Miner. Metall. Mater., 2021, 28(5): 797.