Insulating refractories based on rice husk ashes functionalized by flame-sprayed alumina coatings for steel ingot casting

Abstract

This study investigates a new insulating refractory material based on rice husk ashes (RHA) for its application in the steel ingot casting process. The excellent insulating properties of this material may improve heat- and energy balance during ingot casting. A flame-sprayed alumina coating is applied to provide chemical inertness of the substrate material against the steel melt. The refractoriness, oxidation resistance, phase evolution and thermal expansion of four different grades of RHA materials and phase evolution and thermal expansion of flame-sprayed alumina coatings are studied. The refractoriness of the RHA materials increased with increasing silica content, showing sufficient refractoriness up to 1600°C for SiO2>94wt%. Immersion tests with composite materials made from RHA substrate and a flame-sprayed alumina coating were successfully performed in a steel casting simulator. No deformation of the substrate material nor spalling of the flame-sprayed alumina coating was observed despite an immersion without preheating.