Microstructural and chemical characterization of interpenetrating phase composites as uniquerefractory materials produced via reactive metal penetration

Abstract

Ordinary refractory materials used in industrial processing containment and protection applications currently fail due to: 1) chemical reactions between the materials being processed, 2) mechanical degradation of the refractory material by the process of environmental and 3) temperature limitations on the use of a particular refractory material. Subsequently, industry is constantly searching for new materials that address these limitations.

A refractory production technique refined and commercialized by Fireline TCON, Inc., involving the use of controlled chemical transformations, offers the potential to produce novel refractory materials with greater service lives in harsh industrial production environments, such as molten metal processing. Current materials produced by this TCON process demonstrate promising erosion and corrosion resistance in certain industrial processing environments. These materials, however, possess limited high-temperature strength and thermal shock resistance.

In order to maximize the potential value and assist in the commercialization of TCON materials, there is a need to analyze alternative compositions that will increase the properties of high-temperature strength and thermal shock resistance. The necessary analysis included: optical microscopy (OM), scanning-electron microscopy (SEM), energy dispersive x-ray spectrometry (EDS) and x-ray diffraction (XRD) to visualize the displacement reactions. Furthermore, digital image analysis capabilities furthered the understanding of the chemical reactions that occur. The analysis was then correlated with ambient temperature properties.