THERMAL-STRESS ANALYSIS OF FUSED-CAST AZS REFRACTORIES DURING PRODUCTION .1. INDUSTRIAL-STUDY

A study has been conducted to understand and prevent the formation of cracks in alumina-zirconia-silica (AZS) refractory blocks during solidification processing. A fundamental approach has been taken, centered on the development of a three-dimensional mathematical model to predict heat flow and stress generation in fused-cast AZS refractory blocks. In the first part of a two-part study, the ''voidless'' casting process has been carefully examined in an industrial setting. From a survey of the distribution, frequency of occurrence, and fracture surface morphology of cracks, an attempt was made to link the crack types found in the study to process variables. In-mold temperature data collected for a single casting throughout the normal cooling period have been used to validate the heat-flow model which is described in Part II. The stress analysis, cause of the different cracks, and remedial action are also presented in Part II.