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May 26, 2026Open Ceramics0 citationsOpen Access

Corrosion Behavior of Fused-Cast AZS Refractories in Contact with Barium Crystal Glass

SKSheeraz KhanTrencianska Univerzita Alexandra Dubceka V Trencine AAAhmed Gamal Abd-ElsatarTrencianska Univerzita Alexandra Dubceka V Trencine AOAbel W. OurgessaTrencianska Univerzita Alexandra Dubceka V Trencine

Key Points

This study aims to evaluate the corrosion behavior of fused-cast AZS refractories in contact with barium crystal glass melt.
Static corrosion test (ASTM C621 -9) at 1480°C for 72 hours to simulate industrial conditions.
SEM-EDS and ICP-OES analyses to assess microstructural changes and chemical composition.
Ultrasonic nondestructive testing to detect internal cavities in refractories.
Corrosion depth varied significantly; most severe attack near the glass line.
Zirconia enrichment from 0.03 to 0.46 wt. % and Na₂O depletion from 8.12 to 7.6 wt. % indicate alkali exchange.
Presence of internal cavities detected by ultrasonic testing complemented the corrosion findings.

Abstract

Fused cast (FC) Al₂O₃-ZrO₂-SiO₂ (AZS) based refractories are used to line glass furnaces, enabling them to withstand harsh conditions and temperatures up to 1600°C. However, prolonged exposure to molten glass leads to severe corrosion, shortening the furnace lifespan, reducing efficiency, and introducing defects in the final glass product. This study evaluates the corrosion behavior of commercial FC AZS refractories in contact with barium crystal tableware glass melt. Static corrosion test (ASTM C621 -9) at 1480°C for 72 hours was performed to simulate industrial conditions at a lab-scale to assess corrosion. The corrosion depth varied significantly among the refractory grades, with the most severe attack occurring near the glass line. SEM-EDS analysis revealed the dissolution of the silica-rich vitreous matrix, alkali enrichment, and the formation of needle-like alumina crystals, while zirconia dendrites formed protective structures demonstrating remarkable corrosion resistance. ICP-OES analysis of the reacted glass showed ZrO₂ enrichment (from 0.03 to 0.46 wt. %) and Na₂O depletion (from 8.12 to 7.6 wt. %) indicating alkali exchange at the interface and selective leaching. After corrosion, the reduced peak intensities of corundum and baddeleyite, as the primary crystalline phases of FC-AZS and the presence of an amorphous hump indicated partial dissolution of crystalline phases and surface glass infiltration. Ultrasonic nondestructive testing (NDT) detected internal cavities in the refractory blocks, complementing the corrosion results by revealing hidden voids formed during service exposure. This study provides insights into the dissolution behavior of FC AZS refractory during barium crystal glass production. It highlights microstructural changes along the glass line, such as matrix dissolution, alkali enrichment, and the retention of zirconia dendrites, providing guidance for selecting refractories in next-generation glass-melting technologies.

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