Postmortem analysis of Al2O3–SiC–C refractory in the application of one‐ladle iron‐making technology

Abstract Al 2 O 3 –SiC–C refractory for one‐ladle enterprises technology was prepared using bauxite, SiC, C, pyrophyllite, and corundum as raw materials. The sample composition, phase, structure, and porosity were analyzed at different service degrees. The material exhibited a periodic pattern of destruction during the service process. Carbon oxidation resulted in the formation of a decarburization layer. This led to the formation of a low‐melting phase through combination of slag. This low‐melting phase underwent a reaction and permeation with iron and slag and was then removed through a process of scouring, leaving behind pores and an erosion layer stripped from the material. The formation of a decarburization layer and low‐melting phases reduced the thermal shock resistance of the material, and the structural damage caused by thermal shock accelerated chemical erosion. Furthermore, the penetration of iron into the brick joints contributed to the failure of the material.