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DOI: 10.1111/ijac.14127
RESEARCH ARTICLE
KEYWORDS
alumina spinel castable, calcium hexa-aluminate (CA6 ), fume silica content, preformed and in
situ spinel
Int J Appl Ceram Technol. 2022;19:3311–3322. wileyonlinelibrary.com/journal/ijac © 2022 The American Ceramic Society. 3311
3312 KUMAR and SARKAR
For the individual measurement of each data, an average soaking time of 30 min. HMoR was done with a span
of three values was taken. The hot strength (hot modulus length of 125 mm and a loading rate of 1.3 kg/s. The phase
of rupture [HMoR]) was carried out, on cast samples with analysis study was done on the matrix part of the 1550◦ C
dimension (150 × 25 × 25 mm3 ) and fired at 1550◦ C, in an fired sample using a powder X-ray diffraction technique
HMoR furnace (Bysakh & Co., India-made) with alumina in an X-ray diffractometer (XRD) using Cu Kα radiation
supporting and mullite loading rods at 1400◦ C with a through an Ni filter (Rigaku, Japan made) at a scanning
3314 KUMAR and SARKAR
Density values of preformed and in situ spinel castable F I G U R E 4 Bulk density of preformed spinel castable
with 4% fume silica content and spinel variation 10– composition with 1-wt.% fume silica
30 wt.% and MgO content 2.8–8.4 wt.% are shown in
Figures 2 and 3, respectively. Increasing spinel content
from 10 to 30 wt.% has reduced the bulk density value. strength value.24 The density values with the addition of
The specific gravity of alumina is higher than spinel, so 30-wt.% spinel and 8.4-wt.% MgO with 4 wt.% fume silica
replacing the higher density material with lower density batches have shown inferior properties and have not been
material has reduced the density values.24 Density values considered for further study. So, a study with 1 wt.% fume
for all the compositions are found to be decreasing with silica content was done for 20-wt.% spinel and 5.6-wt.%
an increase in temperature from 110 to 1000◦ C. This was MgO addition for preformed and in situ spinel batches,
mainly due to the breakage of hydraulic bonds in cement respectively.
phases.25,26 As the temperature was increased to 1550◦ C, Figures 4 and 5 represent the density values for pre-
the bulk density value increased for all the compositions. formed and in situ spinel castables with 1 wt.% fume
At 110 and 1000◦ C, the bulk density value for particle size silica content with 10 and 20 wt.% spinel content and 2.8
q = .29 was higher, but at peak temperature, the bulk den- and 5.6-wt.% MgO content, respectively. Preformed spinel
sity value for q = .21 batches was higher. This was mainly castables have a higher density value than MgO containing
due to q = .21 batches having a higher fine content than .29 ones at all temperatures. This might be due to the presence
batches, allowing more sintering and resulting in a higher of loose and bulk natured free MgO and alumina powder
KUMAR and SARKAR 3315
F I G U R E 9 Apparent porosity of in situ spinel castable F I G U R E 1 1 Cold crushing strength of in situ spinel castable
composition with 1-wt.% fume silica composition with 4-wt.% fume silica
F I G U R E 1 2 Cold crushing strength of preformed spinel F I G U R E 1 4 Phase analysis of matrix part of preformed spinel
castable composition with 1-wt.% fume silica composition with fume silica 4 wt.% and q = .21
F I G U R E 1 6 Phase analysis of matrix part of in situ spinel F I G U R E 1 8 Phase analysis of matrix part of preformed spinel
composition with fume silica 4 wt.% and q = .21 composition with fume silica 1 wt.% and q = .21
FIGURE 24 Microstructural and EDS analysis of in situ spinel castable with 2.8-wt.% MgO addition q = .21 and fume silica 4 wt.%
∙ Increasing the spinel content and replacing heavier alu- tion. Also, the presence of a higher amount of spinel or
mina in castable composition reduces the density value. MgO resulted in lower strength.
Also, fired density decreases for both preformed and in ∙ Phase analysis study shows the presence of low melting
situ spinel castables reducing the fume silica content anorthite phase in both the in situ and preformed spinel
reduced from 4 to 1 wt.%, which may be associated with containing fired castables containing 4-wt.% fume sil-
reduced low melting compound formation. ica. However, it is the hibonite (CA6 ) phase in both the
∙ In situ spinel castable has a lower strength value com- castables containing 1-wt.% fume silica.
pared to the preformed one, which may be associated ∙ Significantly higher hot strength values are obtained for
with reduced densification from spinel formation reac- both the castable types containing 1 wt.% fume silica
KUMAR and SARKAR 3321
FIGURE 26 Microstructural and EDS analysis of in situ spinel castable with 2.8-wt.% MgO addition q = .21 and fume silica 1 wt.%
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