Reinforcing Silica Fume and Kaolin with Alumina (Al2O3) and Aluminum Fluoride Trihydrate (AlF3.3H2O) for the Synthesis of Mullite Refractories

https://doi.org/10.65770/IBDQ6493

ABSTRACT

Refractories are well-known ceramics of chemical compositions such as Al2O₃, SiO₂, MgO, etc. Various methods or routes are employed to fabricate refractory materials. Solid-state sintering is the most common and suitable method utilized to fabricate refractories in the laboratory and on a commercial scale. Two experiments were conducted using different raw materials and different stoichiometric quantities. In this research, silica fume (SiO₂ ˃ 99%), kaolin (Al₂Si₂O₅(OH)₄ and alumina (Al₂O₃) were utilized. Silica and kaolin are solid waste materials used as starting materials for synthesizing mullite refractory ceramics. Aluminum fluoride trihydrate was added to the appropriate reacting mixtures to aid the ceramic or refractory formation. 10g of Al₂O₃ and 4g of SiO₂ were measured in the first experiment, while 10.2g of Al₂O₃ and 12.9g of Al₂Si₂O₅(OH)₄ measured in the second experiment. Three specimens were prepared from each of the two sets of prepared mixtures and heated at 1000⁰C. 1100⁰C, and 1200⁰C in the muffle furnace. The specimens were ground into powder form to make them ready for characterization. SEM, XRD, EDS, and FTIR characterizations were done on the specimens to determine the morphology, crystallinity, chemical compositions, functional groups, and absorption frequencies in the fabricated composites.

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