Abstract
Computer modelling is a key tool in the optimisation and development of ceramic refractories utilised as insulation in high-temperature industrial furnaces and reactors. The paper is devoted to the mesoscale computer modelling of silica refractories using the method of homogeneously deformable discrete elements. Approaches to determine the local mechanical properties of the constituents from the global experimental failure parameters and respective crack trajectories are considered. Simulations of the uniaxial compressive and tensile failure in a wide range of quasi-static and dynamic loading rates (102 s−1) are performed. The upper limit of the dynamic loading rates corresponds to the most severe loading rates during the scrap loading on the refractory lining. The dependence of the strength, fracture energy, and brittleness at failure on the loading rate is analysed. The model illustrates that an increase in the loading rate is accompanied by a significant change in the mechanical response of the refractory, including a decrease in the brittleness at failure, a more dispersed failure process, and a higher fraction of the large grain failure. The variation of the grain–matrix interface’s strength has a higher impact on the static compressive than on the static tensile properties of the material, while the material’s dynamic tensile properties are more sensitive to the interface strength than the dynamic compressive properties.
Highlights
Refractories are ceramic materials utilised to construct industrial furnaces and hightemperature reactors [1,2,3,4,5,6,7,8]
Refractories are exposed to mechanical loads of diverse types and intensity [2,3], featuring compressive and tensile stresses resulting from the interactions between different parts of the refractory structure and under the influence of the process conditions
The reference characteristics that were utilised in assessing the accuracy of the mechanical model were the quasi-static values of the ultimate tensile (UTS) and compressive (UCS)
Summary
Refractories are ceramic materials utilised to construct industrial furnaces and hightemperature reactors [1,2,3,4,5,6,7,8]. They have a composite microstructure, which typically features large filler grains, a matrix of smaller grains, pores, and micro-cracks. There exist refractories of different chemical compositions and morphology of microstructure to match different service conditions. Their mechanical behaviour is characterised by the quasi-brittle failure and sensitivity of strength to hydrostatic stress [2,3]. The refractories’ ability to sustain different loads is critical for the reliability and productivity of the high-temperature industrial equipment
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