Abstract
Cost-effective decarbonization and structural strengthening of carbon-containing refractory materials are crucial for the development of low-carbon steel (LCS) and ultra-low-carbon steel (ULCS) technologies. In this study, a carbonaceous-ceramic reinforcement assembly structure composed of multilayer graphenes and silicon carbide whiskers/particles (MLGs-SiCw/SiCp) has been successfully designed and fabricated. By employing three-roll milling (TRM) for low-cost exfoliation of expanded graphite (EG) into MLGs in a phenolic resin (PF) medium, we optimized the exfoliation cycles to fine-tune the morphology of MLGs. Subsequently, the catalytical solid-state conversion of PF/MLGs reacting with Si into SiCw/SiCp at 1400 °C, under varying C/Si molar ratios and catalyst contents, not only retained the structural integrity of MLGs but also embedded them within a novel SiCw/SiCp composite matrix. Our research elucidates the catalytic conversion mechanism, underscoring the significant role of nickel catalysts in promoting efficient SiC conversion. This work offers a promising pathway for developing high-performance, economical, low-carbon refractories.
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