Microstructures and properties of microporous mullite‐corundum aggregates for lightweight refractories

Abstract Five microporous mullite‐corundum refractory aggregates were prepared from Al(OH) ₃ and kaolinite gangue through in situ decomposition synthesis technique. The effects of the sintering temperature (1400–1600°C) and the particle sizes of raw materials (20.6–94.5 μm) on the microstructures and strengths of the aggregates were investigated through X‐ray diffractometer, scanning electron microscopy, and energy‐dispersive spectrometer etc., to find out the technological conditions to be controlled in industrial production. The higher sintering temperature promoted the reaction between Al(OH) ₃ and kaolinite gangue, leading to the development of primary‐mullite as well as the generation of secondary‐mullite, which promoted the formation of the neck and improved the strength. Meanwhile, the dense mullite layers were formed continuously on the surface of Al(OH) ₃ pseudomorphs, making the micropores inside the pseudomorphs become closed pores, which increased the closed porosity of the aggregates. The reduction of the particle sizes of raw materials changed the particle packing behavior, accelerated the rearrangement of the Al(OH) ₃ pseudomorph particles during the process of reactive sintering, and then reduced the closed porosity. To realize the industrial production of microporous mullite‐corundum refractory aggregate with high strength (103 MPa) and high closed porosity (16.1%), the sintering temperature should be at about 1600°C, and the median diameter of raw materials should be at 94.5 μm.