Fracture Toughness and Spalling Behavior of High-Al2O3 Refractories

The fracture energies and spalling resistance of high-Al₂O₃ refractories were studied. The fracture energies, γ _WOF and γ _NBT , were measured by the work-of-fracture and the notched-beam-test methods, respectively. Spalling resistance, as measured by the relative strength retained in a water quench, correlated well with the thermal-stress resistance parameter applicable to stable crack propagation under conditions of thermal shock, (γ _WOF /α² E ₀). Many of the refractories exhibited high ratios of γ_WOF to γ_NBT; such high ratios were shown analytically to maximize the parameter ( R ¹¹¹¹= E _0γWOF/S₁²) which describes the resistance to catastrophic spalling. The increase of crack length with increasing quenching temperature difference (Δ T ) was somewhat less than that predicted theoretically; the discrepancy was attributed to an increase of crack density with Δ T . In general, the results show that fracture energy is important in establishing the spalling resistance of high-Al₂O₃ refractories.