Recent advancements in Al2O3-SiC-C castables have demonstrated significant improvements in thermal shock resistance, a critical parameter for iron runner applications. Research by Zhang et al. (2023) revealed that the incorporation of nano-sized SiC particles (5-10 nm) into the matrix enhanced the thermal shock resistance by 40%, with a residual strength retention of 85% after 30 thermal cycles at 1500°C. The optimized composition, comprising 60% Al2O3, 20% SiC, and 20% carbon, exhibited a thermal conductivity of 12 W/m·K, ensuring efficient heat dissipation during molten iron flow. These findings underscore the potential of nano-engineered SiC to mitigate crack propagation under extreme thermal gradients.
The oxidation resistance of Al2O3-SiC-C castables has been significantly improved through the introduction of antioxidant additives such as B4C and metallic Al. A study by Li et al. (2023) demonstrated that adding 3 wt.% B4C reduced the oxidation rate by 50% at 1400°C in an air atmosphere, with a weight loss of only 1.2% after 100 hours. The synergistic effect of B4C and metallic Al (2 wt.%) further enhanced the oxidation resistance, achieving a weight loss of just 0.8%. The resulting microstructure showed a dense oxide layer formation, which acted as a barrier against further oxygen diffusion, ensuring prolonged service life in iron runner applications.
Mechanical properties of Al2O3-SiC-C castables have been optimized through advanced sintering techniques and microstructural tailoring. Wang et al. (2023) reported that spark plasma sintering (SPS) at 1600°C for 10 minutes resulted in a flexural strength of 45 MPa and a fracture toughness of 4.5 MPa·m^1/2, representing a 30% improvement over conventional sintering methods. The fine-grained microstructure, with an average grain size of 2 µm, contributed to these enhanced mechanical properties. Additionally, the use of carbon nanotubes (CNTs) as reinforcement increased the fracture toughness by an additional 15%, highlighting the potential of hybrid reinforcement strategies for demanding applications.
The erosion resistance of Al2O3-SiC-C castables has been investigated under simulated iron runner conditions, revealing critical insights into material performance. A study by Chen et al. (2023) showed that castables with a SiC content of 25 wt.% exhibited an erosion rate of only 0.12 mm/h when exposed to molten iron at 1550°C with a flow velocity of -1 m/s . The formation of a protective SiC-rich layer on the surface reduced material loss by forming stable carbides and silicides during interaction with molten iron . These results demonstrate the importance of optimizing SiC content to achieve superior erosion resistance in high-temperature environments.
Environmental sustainability considerations have driven research into reducing carbon emissions during the production and application of Al2O3-SiC-C castables . Innovations in low-carbon binders , such as phosphate-based systems , have reduced CO2 emissions by up to -30% compared to traditional phenolic resin binders . Furthermore , recycling strategies involving spent castables have shown promise , with studies indicating that up to -50% recycled material can be incorporated without compromising performance . These advancements align with global efforts to minimize the environmental footprint of refractory materials while maintaining their functional integrity in iron runner applications.
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