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Effect of CaF2 and BaSO4 additives on the corrosion resistance of aluminosilicate castables against molten aluminum.

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Title: Effect of CaF2 and BaSO4 additives on the corrosion resistance of aluminosilicate castables against molten aluminum.
Authors: Zhou, Fangfang1,2 (AUTHOR), Han, Bingqiang1,2 (AUTHOR) hbqref@126.com, Zhong, Hutang1,2 (AUTHOR), Wei, Jiawei3 (AUTHOR), Wei, Yaowu1,2 (AUTHOR), Chen, Junfeng1,2 (AUTHOR), Yao, Xiaoyun4 (AUTHOR)
Source: Ceramics International. Jul2026, Vol. 52 Issue 18, p33113-33122. 10p.
Subjects: Calcium fluoride, Barium sulfate, Liquid aluminum, Microcracks, Corrosion resistance, Corrosion prevention, Minerals, Castable refractories
Abstract: Impermeable materials are crucial for preventing molten electrolyte and aluminum penetration in aluminum electrolytic cells. Although aluminosilicate castables can form a nepheline phase to inhibit electrolyte permeation, they exhibit limited resistance to molten aluminum corrosion. To enhance the resistance of impermeable-layer castables to molten aluminum penetration, the effects of CaF 2 and BaSO 4 additives on the penetration resistance of aluminosilicate castables were comparatively investigated. The results demonstrated that, during molten aluminum attack, molten aluminum reacted with BaSO 4 in the specimen and mullite in the matrix, resulting in the in situ formation of celsian (BaAl 2 Si 2 O 8). Because of its poor wettability toward molten aluminum, celsian formed a protective barrier at the interface, effectively suppressing molten aluminum penetration. By contrast, CaF 2 functions as a strong fluxing agent, promoted excessive liquid-phase formation at high temperatures, disrupted the skeletal structure of bauxite aggregates, and induced microcracks in the castable. Molten aluminum then infiltrated along these microcracks and reacted intensely with SiO 2 via an aluminothermic reduction reaction. The resulting volume expansion further transformed the microcracks into penetration channels, ultimately intensifying molten aluminum attack on the castable. [ABSTRACT FROM AUTHOR]
Copyright of Ceramics International is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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DbLabel: Engineering Source
An: 194968172
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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  Label: Title
  Group: Ti
  Data: Effect of CaF2 and BaSO4 additives on the corrosion resistance of aluminosilicate castables against molten aluminum.
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  Data: <searchLink fieldCode="AR" term="%22Zhou%2C+Fangfang%22">Zhou, Fangfang</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Han%2C+Bingqiang%22">Han, Bingqiang</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> hbqref@126.com</i><br /><searchLink fieldCode="AR" term="%22Zhong%2C+Hutang%22">Zhong, Hutang</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wei%2C+Jiawei%22">Wei, Jiawei</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wei%2C+Yaowu%22">Wei, Yaowu</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Chen%2C+Junfeng%22">Chen, Junfeng</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Yao%2C+Xiaoyun%22">Yao, Xiaoyun</searchLink><relatesTo>4</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Ceramics+International%22">Ceramics International</searchLink>. Jul2026, Vol. 52 Issue 18, p33113-33122. 10p.
– Name: Subject
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  Data: <searchLink fieldCode="DE" term="%22Calcium+fluoride%22">Calcium fluoride</searchLink><br /><searchLink fieldCode="DE" term="%22Barium+sulfate%22">Barium sulfate</searchLink><br /><searchLink fieldCode="DE" term="%22Liquid+aluminum%22">Liquid aluminum</searchLink><br /><searchLink fieldCode="DE" term="%22Microcracks%22">Microcracks</searchLink><br /><searchLink fieldCode="DE" term="%22Corrosion+resistance%22">Corrosion resistance</searchLink><br /><searchLink fieldCode="DE" term="%22Corrosion+prevention%22">Corrosion prevention</searchLink><br /><searchLink fieldCode="DE" term="%22Minerals%22">Minerals</searchLink><br /><searchLink fieldCode="DE" term="%22Castable+refractories%22">Castable refractories</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Impermeable materials are crucial for preventing molten electrolyte and aluminum penetration in aluminum electrolytic cells. Although aluminosilicate castables can form a nepheline phase to inhibit electrolyte permeation, they exhibit limited resistance to molten aluminum corrosion. To enhance the resistance of impermeable-layer castables to molten aluminum penetration, the effects of CaF 2 and BaSO 4 additives on the penetration resistance of aluminosilicate castables were comparatively investigated. The results demonstrated that, during molten aluminum attack, molten aluminum reacted with BaSO 4 in the specimen and mullite in the matrix, resulting in the in situ formation of celsian (BaAl 2 Si 2 O 8). Because of its poor wettability toward molten aluminum, celsian formed a protective barrier at the interface, effectively suppressing molten aluminum penetration. By contrast, CaF 2 functions as a strong fluxing agent, promoted excessive liquid-phase formation at high temperatures, disrupted the skeletal structure of bauxite aggregates, and induced microcracks in the castable. Molten aluminum then infiltrated along these microcracks and reacted intensely with SiO 2 via an aluminothermic reduction reaction. The resulting volume expansion further transformed the microcracks into penetration channels, ultimately intensifying molten aluminum attack on the castable. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Ceramics International is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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      – Type: doi
        Value: 10.1016/j.ceramint.2026.04.359
    Languages:
      – Code: eng
        Text: English
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      Pagination:
        PageCount: 10
        StartPage: 33113
    Subjects:
      – SubjectFull: Calcium fluoride
        Type: general
      – SubjectFull: Barium sulfate
        Type: general
      – SubjectFull: Liquid aluminum
        Type: general
      – SubjectFull: Microcracks
        Type: general
      – SubjectFull: Corrosion resistance
        Type: general
      – SubjectFull: Corrosion prevention
        Type: general
      – SubjectFull: Minerals
        Type: general
      – SubjectFull: Castable refractories
        Type: general
    Titles:
      – TitleFull: Effect of CaF2 and BaSO4 additives on the corrosion resistance of aluminosilicate castables against molten aluminum.
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            NameFull: Zhou, Fangfang
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            NameFull: Han, Bingqiang
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            NameFull: Zhong, Hutang
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            NameFull: Wei, Jiawei
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            NameFull: Wei, Yaowu
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            NameFull: Chen, Junfeng
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            – D: 06
              M: 07
              Text: Jul2026
              Type: published
              Y: 2026
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              Value: 02728842
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              Value: 52
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              Value: 18
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            – TitleFull: Ceramics International
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