New Paradigm for Materials Technology for AZS Glassmaking Refractories

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The project aims to enable the inexpensive manufacture of widely used refractories with reduced energy and materials costs and improved thermal and mechanical properties. The project plans to exploit technology patented by the researchers to fabricate percolated mullite materials from fly ash by sintering, yielding properties equivalent or superior to those of fuse-cast alumina-zirconia-silica refractories (AZS). AZS is expensive since it requires melting by fuse-casting and high-purity raw materials. The project aims to eliminate both requirements by sintering and use of waste fly ash, giving microstructures of dense, direct-bonded, percolated, mullite, single crystals, with residual impurities in the interstices that do not affect creep.