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- Optimização da Técnica de Preparação de Amostras de Betões Refractários Auto-Escoantes de Alumina Sem Cimento Para Observação MicroscópicaPublication . Silva, Abílio P.; Gomes, Ana; Segadães, Ana Maria; Devezas, TessalenoA preparação de amostras para a observação de superfícies em microscopia requer um procedimento de corte, rectificação e polimento rigoroso que obedeça a requisitos sistemáticos de avaliação da qualidade superficial. Neste trabalho, um novo material constituído por 100% de alumina, mas de ingredientes (matriz e agregado) com características distintas obrigou, à implementação de uma nova receita de polimento e de realce dos contrastes entre os elementos estruturais presentes. Assim, apresenta-se um procedimento optimizado para a preparação das amostras de betões refractários auto-escoantes de alumina sem cimento para análise da microestrutura em microscópio metalográfico em complementaridade com o microscópio electrónico de varrimento.
- Designing particle sizing and packing for flowability and sintered mechanical strengthPublication . Silva, Abílio P.; Pinto, Deesy G.; Segadães, A M; Devezas, TessalenoIn this work, alumina powders in five different commercially available size ranges were used to prepare various refractory castable mixtures, defined using the statistical design of mixture experiments (STATISTICA, StatSoft Inc.) and the EMMA 3.3 software (Elkem Materials). Those mixtures were characterized for packing density, Andreasen particle size distribution modulus (q), flowability and after sintering properties, in order to investigate the relationships between these variables. The optimization of matrix and aggregate sizes and matrix-aggregate proportion, subjected to different property requirements, brought to light the relationships between q, specific surface area (SSA) and maximum paste thickness (MPT). Those relationships were investigated for three fundamental processing steps, namely, dry powders, fresh paste and consolidated dried and sintered bodies. The optimized all-alumina castable was found to require 47.5wt.% of a fine size matrix with high flowability, which provides the necessary flow bed for 52.5wt.% of coarse aggregates, resulting in a gap-sized particle size distribution, and presented a fresh paste flowability index above 130% with minimum added water (28mg/m2) and sintered modulus of rupture above 50MPa.
- Effect of particle size distribution and calcium aluminate cement on the rheological behaviour of all-alumina refractory castablesPublication . Silva, Abílio P.; Segadães, A M; Pinto, Deesy G.; Oliveira, Luiz A.; Devezas, TessalenoPrevious works based on statistical design of experiments (DoE) defined a model all-alumina self-flow refractory castable (SFRC) with optimized particle size distribution for simultaneous high flowability index (FI) and superior post-sintering performance. This work compares the SFRC rheological behaviour and setting time with those of alternative all-alumina castables with different Andreasen aggregate particle size distribution modulus, and of the equivalent castables containing calcium aluminate cement. The model castable showed Bingham behaviour with low yield stress, viscosity and thixotropy, guaranteeing easier casting and less wear in the casting and/or projection equipment. However, as the coarse particle fraction increases, the castable flow tends to be non-linear and changes from Bingham to Herschel–Bulkley. The cement containing castables quickly loose flowability despite the applied shear. This work confirmed previous conclusions based on FI measurements and demonstrates the adequacy of the use of FI values in the calculation of FI response surface by DoE.
- Thermomechanical evaluation of self-flowing refractory castables with and without the addition of aluminate cementPublication . Pinto, Deesy G.; Silva, Abílio P.; Segadães, A M; Devezas, TessalenoMuch has been discussed about the advantages regarding the thermomechanical performance of self-flow refractory castables (SFRC), with very little or no addition of calcium aluminate cement (CAC) when compared to conventional composites with cement. Previous works demonstrated that a 100% alumina SFRC with optimized particle size distribution simultaneously results in high-flowability fresh paste and high mechanical strength. In this work, the thermomechanical behaviour of zero-cement ceramic matrix is compared to that of the equivalent composite with 1% CAC content. The results show that the differences in performance can be related to differences in hydration mechanisms, namely the formation sequence of calcium aluminate hydrates, which results in increased open porosity. With lower dried strength, the all-alumina castable presents lower porosity, higher mechanical strength and uncompromised thermal shock resistance, being a valuable option when fast drying or rough green handling can be avoided.
- Castable systems designed with powders reclaimed from dismantled steel induction furnace refractory liningsPublication . Silva, Abílio P.; Segadães, A M; Lopes, Rogério A.Despite environmental pressures and intrinsic recycling potential, spent refractories waste is generally considered an economically unattractive waste stream. This work proposes an upgraded view of the debris recovered from dismantled spinel-bonded high-alumina linings of steel induction furnaces, demonstrating that it can be reused in the form of vibratable and self-flowing castable systems. The recovered material retains the microstructural distribution of in situ spinel formation without the corresponding disruptive expansion, mirroring the use of pre-formed spinel without the onus of a pre-firing. The mechanical performance after firing was found to be always best for the self-flowing system, which is also less affected by changes in added-water content. There is potential for large usages of cleaned waste (50–60 wt%), which helps reducing the supply risk for major refractory primary raw materials as well as landfilling costs.