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<p>This study utilized copper slag tailings, fly ash, and waste glass as raw materials to prepare self-foaming glass-ceramics through the powder sintering method, revealing a dual-reaction coupled foaming mechanism. The research demonstrated that the carbothermal reduction reaction between Fe<sub>2</sub>O<sub>3</sub> in CST and carbon in fly ash, synergized with high-temperature thermal decomposition, enabled in situ gas generation and foam structure regulation at 1160&#xa0;°C. Experimental results showed that with increasing CST content, pore size exhibited an initial increase followed by a decrease, while bulk density and compressive strength first decreased and then increased, attributed to excessive Fe<sub>2</sub>O<sub>3</sub> content inhibiting the foaming process. Elevating sintering temperature and prolonging holding time promoted more complete foaming reactions, resulting in enlarged pore sizes and reduced compressive strength. Optimal performance was achieved with 30 wt% CST content, sintering at 1160&#xa0;°C for 100&#xa0;min, yielding material with 60.8% porosity, 1.09&#xa0;g/cm<sup>3</sup> bulk density, and 8.92&#xa0;MPa compressive strength. Notably, crystallinity remained stable across varying parameters. This research provides theoretical foundation and process optimization pathways for solid waste synergy in preparing high-performance foam glass-ceramics.</p> Graphical Abstract <p></p>

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Preparation, Characterization, and Self-Foaming Mechanism of Foam Glass-Ceramics from High Iron Copper Slag Tailings

  • 期刊论文

  • 发表日期：

    2025年7月5日

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  • Zhuyue Zhang,
  • Lisi Liang,
  • Lixing Zhang,
  • Jin Chen,
  • Zhongyi Cui,
  • Zeming Wang,
  • Jiajun Xi,
  • Jiahui Chai,
  • Gexuan Ning

摘要

This study utilized copper slag tailings, fly ash, and waste glass as raw materials to prepare self-foaming glass-ceramics through the powder sintering method, revealing a dual-reaction coupled foaming mechanism. The research demonstrated that the carbothermal reduction reaction between Fe2O3 in CST and carbon in fly ash, synergized with high-temperature thermal decomposition, enabled in situ gas generation and foam structure regulation at 1160 °C. Experimental results showed that with increasing CST content, pore size exhibited an initial increase followed by a decrease, while bulk density and compressive strength first decreased and then increased, attributed to excessive Fe2O3 content inhibiting the foaming process. Elevating sintering temperature and prolonging holding time promoted more complete foaming reactions, resulting in enlarged pore sizes and reduced compressive strength. Optimal performance was achieved with 30 wt% CST content, sintering at 1160 °C for 100 min, yielding material with 60.8% porosity, 1.09 g/cm3 bulk density, and 8.92 MPa compressive strength. Notably, crystallinity remained stable across varying parameters. This research provides theoretical foundation and process optimization pathways for solid waste synergy in preparing high-performance foam glass-ceramics.

Graphical Abstract