Service life prediction for refractory materials

Ultrasonic pulse velocity testing and image analysis were used to predict the thermal stability of cordierite–mullite refractories. Two compositions used as substrates in fast firing of porcelain whiteware, characterized by different microstructure and crack propagation behavior, were investigated. Fracture strength and fracture toughness values were obtained from three point bending test and chevron notched specimen technique, respectively. The measurement of the ultrasonic velocity was used to assess the material degradation with increasing number of thermal-shock cycles and specimen damage was monitored using image analysis to obtain further evidence of material degradation. The correlation between thermo-mechanical properties, ultrasonic velocity, microstructure, crack-propagation behavior and thermal-shock resistance was discussed. A remarkable similarity was found between the variation of ultrasonic velocity (when measured through the length of the refractory plates) and fracture strength with number of thermal shock cycles. On the other hand, the development of surface microcracking, as monitored by image analysis, is in good agreement with the variation of K IC with the number of thermal-shock cycles. The variation of the $$\frac{d\sigma_{\rm f}}{dE_{\rm dyn}}$$ ratio with number of thermal-shock cycles shows the highest gradient of the investigated trends and it is proposed as a promising parameter to differentiate refractory materials regarding their different thermal shock behavior. Service life prediction models for refractory plates, from measured values of ultrasonic velocity and surface damage analysis, were proposed and validated.