Synthesis of an innovative zirconia-mullite raw material sintered from andalusite and zircon precursors and an evaluation of its corrosion and thermal shock performance

This paper deals with the synthesis and the properties of an innovative zirconia-mullite raw material sintered from an andalusite/alumina/zircon mix. The microstructure of these composite grains consists of fine zirconia particles in a mullite matrix. This study highlights that the synthesis process (sintering from SiO₂.Al₂O₃, Al₂O₃ and ZrSiO₄ raw materials) plays an essential role in the improvement of both the corrosion resistance to alumina-lime slag and soda-lime glass and the thermal shock resistance of this refractory. The microstructural observations correlated with non-destructive characterizations, ultrasonic pulse echography and acoustic emission techniques, underline the repairing mechanism exhibited by this material after experiencing repeated thermal shock.