In situ Spinel Expansion Design by Colloidal Alumina Suspension Addition

The incorporation of nano powders into refractory castables it is not a straightforward procedure, due to their agglomeration and sintering drawbacks. Considering the alumina grain size effect on the in situ spinel formation and the associated overall volumetric expansion, alumina-magnesia refractory castables containing different alumina sources were evaluated by the assisted sintering technique. Reducing the size of fine tabular alumina (< 200 mu m) led to lower expansion levels, indicating the main role of alumina grain size in this property. Regarding the reactive aluminas (nano alumina powder, hydratable alumina, and colloidal alumina), the composition containing colloidal alumina performed remarkably better, leading to the lowest in situ spinel expansion level as a consequence of its high sinterability. The use of nano scaled alumina suspensions was the most suitable alternative to inhibit the shortcoming of nano powder agglomeration. Conversely, the castable containing the nano alumina powder did not behave as expected. The present work pointed out that the use of nano powders in refractory castables is only feasible if the compound is fully dispersed. Otherwise, cheaper raw materials could provide even better results than those of nano agglomerated powders.