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Direct synthesis of porous calcium-hexaluminate aggregate for refractory applications

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Abstract

The synthesis of macro-porous calcium-hexaluminate (CaO∙6Al2O3, CA6) aggregates composed of CA6 platelets was examined using various Ca- and Al-precursors. The effects of annealing temperature, time, atmosphere, and AlF3 as a mineralizer on the formation of plate-shaped CA6 were also studied. The Ca:Al ratio was adjusted for full conversion to CA6, which is the most stable phase among the CaO-Al2O3 intermediate compounds. The conditions for the synthesis of plate-shaped CA6 aggregates with adequate strength were uncompromising, requiring heat treatment at ≥ 1500 °C for 15 h, which was also significantly affected by the type and size of the precursors. CA6 aggregate synthesized directly using coarse Al2O3 and CaO with 10 wt% CaO∙Al2O3 cement as a binder phase revealed the optimal macro-porous microstructure for castable refractory applications, showing porosity and compressive strength of 65% and 2.9 MPa, respectively.

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Acknowledgements

This study was supported by the Technology Innovation Program (20012911) funded by the Korean Ministry of Trade, Industry & Energy. The authors also thank the Core Research Support Center for Natural Products and Medical Materials (CRCNM) for technical support regarding the porosimetry measurements.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Yeungnam University, Gyeongsan, 38541, South Korea

    Hyeon-Mo Bae, Ayman Muhammad Tsabit & Dang-Hyok Yoon

  2. Engineering Ceramic Center, Korea Institute of Ceramic Engineering and Technology, Icheon, 17303, South Korea

    Sung-Soo Ryu

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Bae, HM., Tsabit, A.M., Ryu, SS. et al. Direct synthesis of porous calcium-hexaluminate aggregate for refractory applications. J. Korean Ceram. Soc. 61, 104–114 (2024). https://doi.org/10.1007/s43207-023-00352-y

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