Developing novel macro and micro structures to create tailored materials properties for advanced refractory materials

This is an EngD project - not a PhD - please see our programme web pages http://www.surrey.ac.uk/minmat/

Vesuvius is a world leader in the development, production and deployment of advanced refractory ceramic materials for use in the metals processing industries. Currently, such ceramic materials are fully dense and tend, in the main, to be manufactured using traditional ceramic manufacturing techniques. Traditional materials operate at up to 1500°C and are typically based on Alumina, Aluminosilicate or Magnesia based ceramics with production levels reaching thousands of tonnes per annum.

To increase the efficiency of materials usage and manufacturing processes this study aims to develop a novel manufacturing route for the manufacture of density graded refractory ceramic components. The programme of work will identify ways in which the micro- and macro-structure of ceramic materials can be tailored through the inclusion of controlled porosity during the manufacturing stages. This will be achieved through the use of suitable in-situ foaming techniques and additive manufacturing routes, such as spray deposition, designed to minimise materials wastage.

The effect of the level of porosity, as well as pore morphology, distribution and connectivity will be evaluated with specific reference to performance critical properties including strength at temperature, thermal shock resistance and thermal conductivity. In addition, the material interaction with molten metals will be evaluated to understand how the surface layer affects the service life of the refractory structure.

A review of existing pore forming manufacturing techniques will be used to inform the development of the manufacturing technique with testing and microstructural characterisation being used to tailor the process and build an understanding of the structure-performance relationship. This will allow the customer benefits of the new product to be identified, characterised and quantified. Target benefits may include, but will not be limited to, reduced material content, reduced energy consumption, reduced carbon footprint, and improvements in key materials properties such as thermal conductivity.


80% of programme time will be spent on sponsor premises