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<p>Conventional lightweight refractory materials with low bulk density and more pores suffer from harsh corrosion and erosion in actual applications. A type of lightweight Al<sub>2</sub>O<sub>3</sub>–MgAl<sub>2</sub>O<sub>4</sub> aggregates with a core–shell structure was synthesized at 1750&#xa0;°C using a rolling granulation method. Microstructural evolution and properties of the spherical aggregates were systematically studied. Scanning electron microscope and X-ray computed tomography results confirmed that a continuous and dense MgAl<sub>2</sub>O<sub>4</sub> spinel shell structure with a thickness of 200–300&#xa0;μm was formed on the surface. The corrosion results indicated that the corrosion index of the core–shell aggregates exhibited a 60% enhancement when compared to Al<sub>2</sub>O<sub>3</sub> spherical. Moreover, Al<sub>2</sub>O<sub>3</sub>–MgAl<sub>2</sub>O<sub>4</sub> refractory materials, which are based on the lightweight Al<sub>2</sub>O<sub>3</sub>–MgAl<sub>2</sub>O<sub>4</sub> spherical aggregates, possessed a higher temperature modulus of rupture of 9.19&#xa0;MPa, and the retention rate of residual flexural strength reached 70% after thermal shock testing. The above results showed an improvement of 129.75 and 44.28% compared with pure Al<sub>2</sub>O<sub>3</sub> aggregate samples, respectively. In addition, the MgAl<sub>2</sub>O<sub>4</sub> spinel shell could trap the Mn, Fe elements from infiltrated slag and transfer into (Mg, Fe, Mn) Al<sub>2</sub>O<sub>4</sub> spinel, infiltrated CaO reacts with Sample Al<sub>2</sub>O<sub>3</sub> matrix to form a calcium hexaluminate (CA<sub>6</sub>) isolation layer, and the above two reasons enhance the corrosion resistance of the material. The corrosion mechanism was elaborated in detail.</p>

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Fabrication of lightweight Al2O3@MgAl2O4 spherical aggregates and its influence on corrosion resistance and thermomechanical properties

  • 期刊论文

  • 发表日期：

    2026年2月17日

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  • Jiang-Yun Bai,
  • Jun-Feng Chen,
  • Xiang-Shuai Hou,
  • Shi-Kui Lu,
  • Fan Bai,
  • Wen Yan,
  • Yao-Wu Wei,
  • Shao-Wei Zhang,
  • Nan Li,
  • Yu Zhang

摘要

Conventional lightweight refractory materials with low bulk density and more pores suffer from harsh corrosion and erosion in actual applications. A type of lightweight Al2O3–MgAl2O4 aggregates with a core–shell structure was synthesized at 1750 °C using a rolling granulation method. Microstructural evolution and properties of the spherical aggregates were systematically studied. Scanning electron microscope and X-ray computed tomography results confirmed that a continuous and dense MgAl2O4 spinel shell structure with a thickness of 200–300 μm was formed on the surface. The corrosion results indicated that the corrosion index of the core–shell aggregates exhibited a 60% enhancement when compared to Al2O3 spherical. Moreover, Al2O3–MgAl2O4 refractory materials, which are based on the lightweight Al2O3–MgAl2O4 spherical aggregates, possessed a higher temperature modulus of rupture of 9.19 MPa, and the retention rate of residual flexural strength reached 70% after thermal shock testing. The above results showed an improvement of 129.75 and 44.28% compared with pure Al2O3 aggregate samples, respectively. In addition, the MgAl2O4 spinel shell could trap the Mn, Fe elements from infiltrated slag and transfer into (Mg, Fe, Mn) Al2O4 spinel, infiltrated CaO reacts with Sample Al2O3 matrix to form a calcium hexaluminate (CA6) isolation layer, and the above two reasons enhance the corrosion resistance of the material. The corrosion mechanism was elaborated in detail.