Fracture behavior of Al2O3–SiO2 castables by the wedge splitting test and digital image correlation technique

The fracture mechanisms are helpful for the optimization and design of toughness and microstructure of refractories. Fracture behavior of ultra-low cement bonded Al₂O₃–SiO₂ castables was researched using the wedge splitting test coupled with digital image correlation technique (WST-DIC). Flexibility of Al₂O₃–SiO₂ castables is improved by introducing andalusite aggregates into the castables. The characteristic length L_CH, a parameter used to assess flexiblity of materials, was observed to reach 287.2 mm in andalusite-containing Al₂O₃–SiO₂ castables, more than 5 times that of reference castables. Microcracks toughening is the main toughening mechanisms for flexibility improvement of the Al₂O₃–SiO₂ castables containing andalusite. Microcrack network in the Al₂O₃–SiO₂ castables could be designed by exploiting the volume expansion caused by mullitization of andalusite and the coefficient of thermal expansion (CTE) mismatch between the andalusite aggregate and the matrix. Unlike andalusite-free castables, castables containing andalusite possess a distinct fracture process zone (FPZ), the crack branching and deflection can be observed around the main crack during the fracture process, which leads to the prolong of the crack propagation path, the increase of the dissipation energy during the fracture, and the enhancement of resistance to crack propagation.