Development of cordierite-mullite refractory castables bonded with magnesium silicate hydrate cement
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Abstract
Cordierite-mullite refractory materials are widely used as kiln furniture in the ceramic industry due to their excellent thermal shock resistance and high mechanical strength at elevated temperatures. Cordierite-mullite ceramics possess excellent mechanical strength and thermal shock resistance, making them well-suited for kiln furniture. This research explores the development of cordierite-mullite refractory castables using a magnesium silicate hydrate (MSH) cement as a novel bonding system. Castables were prepared with varying molar ratios of MgO to SiO2 (0.75 to 4) and characterized for their physical, mechanical, and thermal properties. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses revealed the formation of MSH cement phase at room temperature, which decomposed upon firing to form spinel and ultimately cordierite at high temperatures. The optimal MgO to SiO2 molar ratio of 1 yielded the best physical properties, including a modulus of rupture of 13.41 MPa after sintering at 1350 °C, bulk density of 2.01 g/cm³, porosity of 22.45%, and thermal expansion coefficient of 2.59 x 10-6 °C-1. The microstructural evolution showed the transformation from loosely bound particles in the green state to a well-sintered cordierite matrix embedding mullite aggregates after firing. The developed castables exhibited properties comparable to commercial cordierite-mullite kiln furniture, demonstrating their potential as a viable option for high-temperature ceramic applications.
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