Fabrication of low conductivity and high strength MgO-MgAl2O4 aggregates with sub-micron pore structure

Abstract

Lightweight MgO-MgAl2O4 refractory aggregates were fabricated by using fine MgO and spherical Al(OH)3 powders as starting materials. The evolutions of microstructure and pores and their effects on the properties of the specimens were investigated. During heating process, MgO crystallites diffused into the formed Al2O3 pseudomorph, producing sub-micron intra-particle pores in both MgAl2O4 cores and MgO matrix. Besides, larger inter-particle pores between the MgAl2O4 cores and MgO matrix were occurred, attributing to the Kirkendall effect resulting from in-situ spinalization. As MgO content increased from 50 wt% to 80 wt%, due to reduction of the number of the porous MgAl2O4 cores, the inter-particle pores caused by Kirkendall effect decreased sharply in both number and size, while no obvious changes occurred in the intra-particle pores as the porous MgO matrix amount increased simultaneously. The decrease of large inter-particle pores caused obvious improvement in strength but slight increase in thermal conductivity. With a further increase of MgO to 90 wt%, as the number of the porous MgAl2O4 cores reduced further and the MgO matrix densification improved obviously, intra-particle pores and thermal insulation performance reduced significantly. The specimen with 80 wt% MgO showed the best performance, with a median pore diameter of 0.26 μm, apparent porosity of 36.0 %, flexural strength of 23.9 MPa, and thermal conductivity of 2.1 W/(m·K) at 500 °C.