Skip to main content
SpringerLink
Log in

Effects of Different Barium Compounds on the Corrosion Resistance of Andalusite-Based Low-Cement Castables in Contact with Molten Al-Alloy

  • Published:
Metallurgical and Materials Transactions B Aims and scope Submit manuscript

Abstract

An experimental study was conducted to investigate the interfacial phenomena between an Al alloy and andalusite low-cement castables (LCCs) containing fixed contents of barium compounds (BaO, BaSO4, and BaCO3) at 1123 K and 1433 K (850 °C and 1160 °C) using the Alcoa cup test. Interfacial reaction products and phases formed during heat treatment of the refractory samples were characterized using scanning electron microscopy (SEM) coupled with energy dispersive spectrometry (EDS) and X-ray diffraction analysis (XRD). The addition of both BaO and BaSO4 led to a significant reduction of alloy penetration into the refractory. Hexa-celsian formation was observed in both these refractories, which drastically increased their corrosion resistance. Barite decomposition was observed at 1373 K (1100 °C) in the presence of alumina and silica, which was the precursor for hexa-celsian formation. Barium silicates were formed in all samples containing additives; however, this did not have any major influence on the corrosion resistance. Solidified eutectics of BaSi2 and α-BaAl2Si2 formed in all these samples, which acted as an interfacial barrier that prevented additional molten aluminum penetration; however, the positive effect of intermetallic formation was offset by glassy phase formation in samples containing BaCO3 as the additive.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

References

  1. P. Koshy, S. Gupta, V. Sahajwalla, and P. Edwards: J. Mater. Sci., 2010, vol. 46, no. 2, pp. 468-78.

    Article  Google Scholar 

  2. C. Allaire and M. Guermazi: Proc. Int. Symp. Light. Metal, J. Kazadi and J. Masounave, eds., Ottawa, Ontario, Canada, 2000, pp. 685–91.

  3. W.T. Choate and J.A.S. Green: US Energy Requirements for Aluminum Production: Historical Perspective, Theoretical Limits and New Opportunities. US Department of Energy, Washington, D.C., 2003.

  4. K.J Brondyke: J. Am. Ceram. Soc., 1953, vol. 36, no. 5, pp. 171-74.

    Article  CAS  Google Scholar 

  5. U.S. Department of Energy: U.S. Energy Requirements for Aluminum Production, U.S. Department of Energy, Prepared for the Energy Efficiency and Renewable Energy Industrial Technologies Program, Washington, D.C., 2003.

  6. P. Koshy, S. Gupta, V. Sahajwalla, and P. Edwards: Metall. Mater. Trans. B, 2008, vol. 39B, pp. 603-12.

    Article  CAS  Google Scholar 

  7. R. Asthana and N. Sobczak: JOM-e: Overview, TMS, Warrendale, PA, 2000.

  8. X. Zhou and J.T.M. De Hosson: Acta Mater., 1996, vol. 44, no. 2, pp. 421-26.

    Article  CAS  Google Scholar 

  9. A. Mortensen, B. Drevet, and N. Eustathopoulos: Scripta Mater., 1997, vol. 36, no. 6, pp. 645-51.

    Article  CAS  Google Scholar 

  10. N. Eustathopoulos, N. Sobczak, A. Passerone, and K. Nogi: J. Mater. Sci., 2005, vol. 40, pp. 2271-80.

    Article  CAS  Google Scholar 

  11. W.E. Lee and S. Zhang: 9th Symp. Refractories for the Aluminum Industries, G. Oprea, ed., TMS, Warrendale, PA, 2000, pp. 177–87.

  12. M.N.I. Castro, J.M.A. Robles, D.A.C. Hernandez, J.C.E. Bocardo, and J.T. Torres: Cram. Int., 2010, vol. 36, pp. 1205-10.

    Article  Google Scholar 

  13. W.S. Resende, C. Zirpoli, G.L. Da Silva, and S.A. Sucupira: Refr. Appl. News, 2002, vol. 7, no. 1, pp. 20-24.

    CAS  Google Scholar 

  14. M. Ksiazek, N. Sobczak, B. Mikulowski, W. Radziwill, and I. Surowiak: Mater. Sci. Eng., 2002, vol. 324A, pp. 162-67.

    Google Scholar 

  15. G. Levi and W.D. Kaplan: Acta Mater., 2002, vol. 50, pp. 75-88.

    Article  CAS  Google Scholar 

  16. G. Levi and W.D. Kaplan: Acta Mater., 2003, vol. 51, pp. 2793-2802.

    Article  CAS  Google Scholar 

  17. E. Saiz, A. Tomsia, and K. Suganuma: J. Eur. Ceram. Soc., 2003, vol. 23, pp. 2787-96.

    Article  CAS  Google Scholar 

  18. N. Sobczak, M. Ksiazek, W. Radziwill, R. Asthana, and B. Mikulowski: Metall. Mater. Trans. A, 2004, vol. 35A, pp. 911-23.

    Article  CAS  Google Scholar 

  19. P.D. Ownby, K.W.K. Li, and D.A. Weirauch, Jr.: J. Am. Ceram. Soc., 1991, vol. 74, no. 6, pp. 275-81.

    Article  Google Scholar 

  20. O.-J. Siljan and C. Schoning: Refr. Appl. News, 2002, vol. 8, no. 1, pp. 21-29.

    Google Scholar 

  21. O.-J. Siljan, G. Rian, D.T. Petterson, A. Solheim, and C. Schoning: Refr. Appl. News, 2002, vol. 7, no. 6, pp. 19-25.

    Google Scholar 

  22. S. Afshar and C. Allaire: JOM, 2000, vol. 52, no. 5, pp. 43-46.

    Article  CAS  Google Scholar 

  23. M.E. Perron and C. Allaire: J. Can. Ceram. Soc., 2000, vol. 69, no. 20, pp. 31-35

    CAS  Google Scholar 

  24. S. Afshar and C. Allaire: JOM, 2001, vol. 53, no. 8, pp. 24-27.

    Article  CAS  Google Scholar 

  25. K.T. Raić, T. Volkov-Husović, and R. Jančić: Metalurgija Mjom., 2004, vol. 10, no. 1, pp. 37-50.

    Google Scholar 

  26. M. Allahevrdi, S. Afshar, and C. Allaire: JOM, 1998, vol. 50, no. 2, pp. 30-34.

    Article  CAS  Google Scholar 

  27. S. Lee and D.K. Kim: Ceram. Eng. Sci. Proc., 1990, vol. 11, nos. 7/8, pp. 795-805.

    Article  CAS  Google Scholar 

  28. J.A. Santillan: J. Nanomaterials, 2008, vol. 2008, pp. 1-12.

    Article  Google Scholar 

  29. P. Meunier and S. Pagnier: 49th Int. Feuerfest-Kolloquium on Refractories, Aachen, Germany, 2006, pp. 171-74.

    Google Scholar 

  30. G. Victor and I. Exner: UNITCER 99, Berlin, Germany, 1999, pp. 380-83.

    Google Scholar 

  31. M. Oliveira, S. Agathopoulos, and J.M.F Ferreira: J. Mater. Res., 2002, vol. 17, no. 3, pp. 641-47.

    Article  CAS  Google Scholar 

  32. M. Oliveira, S. Agathopoulos, J. Lino, and J.M.F. Ferreira: J. Mater. Sci. Forum, 2004, vols. 455-456, pp. 39-643.

    Google Scholar 

  33. M. Oliveria, S. Agathopoulos, and J.M.F. Ferreira: Acta Mater., 2002, vol. 50, pp. 1441-51.

    Article  Google Scholar 

  34. C. Allaire: J. Can. Ceram. Soc., 2000, vol. 69, no. 1, pp. 14-20.

    CAS  Google Scholar 

  35. A.K. Chakraborty: J. Thermochim. Acta., 2003, vol. 398, pp. 203-09.

    Article  CAS  Google Scholar 

  36. S. Afshar, C. Gaubert, and C. Allaire: JOM, 2003, 55, no. 4, pp. 66-69.

    Article  CAS  Google Scholar 

  37. Z. Minghua: Masters Thesis, Ecole Polytechnique, Montreal, Canada, 2004

  38. D. Shukla and J.D Smith: J. Refr. Appl. Trans., 2009, vol. 4, no. 3, pp. 2-8.

    CAS  Google Scholar 

  39. P. Hubert: Tehran Int. Conf. on Refractories, 2004, pp. 434–43.

  40. D. Shukla: J. Ref. Appl. News, 2007, vol. 12, no. 6, pp. 23-26.

    CAS  Google Scholar 

  41. A. Albers and J. Baldo: Light Metals Age, 2001, vol. 5, pp. 34-41.

    Google Scholar 

  42. J. Goa: Masters Thesis, Ecole Polytechnique, Montreal, Canada, 2003.

  43. E.A. Firoozjaei, A. Saidi, A. Monshi, and P. Koshy: Ceramica, 2010, vol. 56, no. 4, pp. 411-21.

    CAS  Google Scholar 

  44. J.G. Hamrick, W.L. Headrick, and K.M Peters: Int. J. Appl. Ceram. Tech., 2008, vol. 5, no. 3, pp. 265-77.

    Article  Google Scholar 

  45. P. Koshy: Ph.D. Dissertation, University of New South Wales, Sydney, Australia, 2009.

  46. G. Furness and A. Forde: 128th TMS Annual Meeting, San Diego, CA, TMS, Warrendale, PA, 1999, pp. 975-93.

    Google Scholar 

  47. E. Candan: Turkish J. Eng. Env. Sci., 2002, vol. 26, pp. 1-5.

    CAS  Google Scholar 

  48. C. Allaire and M. Guermazi: Modern Casting, 2000, vol. 90, no. 4, pp. 45-48.

    CAS  Google Scholar 

  49. H. Schmutzler and K. Sandhage: Metall. Mater. Trans B, 1995, vol. 26B, pp. 135-48.

    Article  CAS  Google Scholar 

  50. N.P. Bansal: J. Mater. Sci., 1998, vol. 33, no. 19, pp. 4711-15.

    Article  CAS  Google Scholar 

  51. Y. Kobayashi: Ceram. Int., 2001, vol. 27, no. 2, pp. 179-84.

    Article  CAS  Google Scholar 

  52. C. Allaire: Aluminum. Trans., 2000, vol. 3, no. 1, pp. 105-20.

    CAS  Google Scholar 

  53. W.D. Kingery, H.K. Bowen, and D.R. Uhlmenn: Introduction to Ceramics, 2nd ed., Wiley, New York, NY, 1960, p. 95.

    Google Scholar 

  54. I. Arvanitidis, D. Sichen, and S. Seetharaman: Metall. Mater. Trans. B, 1996, vol. 27B, pp. 409–16.

    Article  CAS  Google Scholar 

  55. E.M. Levin, H.F. McMurdie, and F.P. Hall: Phase Diagram for Ceramists, M.K. Reser, ed., American Ceramic Society, Columbus, OH, 1956.

  56. F. Simonin, C. Olagnon, S. Maximilien, G. Fantozzi, L. Diaz, and R. Torrecillas: J. Am. Ceram. Soc., 2000, vol. 83, no. 10, pp. 2481-90.

    Article  CAS  Google Scholar 

  57. E. AdabiFiroozjaei, A. Saidi, A. Monshi, and P. Koshy: Metall. Mater. Trans. B, 2011, vol. 42B, pp. 400-11.

    Article  Google Scholar 

  58. E. Bruno and G. Gazzoni: Contrib. Mineral. Petrol., 1970, vol. 25, no. 2, pp. 144-52.

    Article  CAS  Google Scholar 

  59. K.H. Sandhage, S.M. Allameh, and X-D. Zhang: Processing and Fabrication of Advanced Material VI, K.A. Khor, T.S. Srivatsan, and J.J. Moore, eds., The Institute of Materials, London, UK, 1998, pp. 763–74.

  60. C.A. Sorrell: Am. Mineral, 1962, vol. 47, pp. 291-309.

    CAS  Google Scholar 

  61. Z.D. Kovziridze and G.V. Khennike: Glass. Ceram., 1982, vol. 39, no. 5, pp. 21–23.

    Article  Google Scholar 

  62. G. Petzow and G. Effenberg: Ternary Alloys, Wiley-VCH, Weinheim, Germany, 1988, p. 312.

Download references

Acknowledgments

The authors acknowledge Amol Refractory Industries Co. Ltd. (Amol, Iran) for their financial and technical support.

Author information

Authors and Affiliations

  1. Department of Materials Engineering, Isfahan University of Technology, Isfahan, 8415683111, Iran

    Esmaeil AdabiFiroozjaei (Graduate M.Sc. Student) & Ebad Rastkerdar (Graduate M.Sc. Student)

  2. School of Materials Science and Engineering, University of New South Wales, Sydney, NSW, 2052, Australia

    Pramod Koshy (Research Associate)

Authors
  1. Esmaeil AdabiFiroozjaei
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Pramod Koshy
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Ebad Rastkerdar
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Esmaeil AdabiFiroozjaei.

Additional information

Manuscript submitted December 24, 2010.

Rights and permissions

Reprints and permissions

About this article

Cite this article

AdabiFiroozjaei, E., Koshy, P. & Rastkerdar, E. Effects of Different Barium Compounds on the Corrosion Resistance of Andalusite-Based Low-Cement Castables in Contact with Molten Al-Alloy. Metall Mater Trans B 42, 901–913 (2011). https://doi.org/10.1007/s11663-011-9522-5

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11663-011-9522-5

Keywords

Search

Navigation