Corrosion Behavior of Al2O3‐C Refractories with Casting Mould Meniscus Slags at 1 550 °C

The degradation behavior of alumina (10–20 wt%) carbon refractories was investigated during high temperature (1 550 °C) contact with a ternary casting mould meniscus slag containing 50% MnO, 25% SiO2, and 25% Al2O3 and a binary slag containing 40% MnO and 60% SiO2. Using the sessile drop approach, the transient progress of corrosion reactions was investigated as a function of time and refractory composition. An in‐depth characterization and analysis of reacted assemblies was carried out using optical and scanning electron microscopy (SEM). Optical micrographs showed a significant penetration of both slags within the refractory substrate, with very little slag remaining behind after 15 min of contact. The depth of penetration of ternary slag was found to increase with carbon concentration in the refractory. An all‐round corrosion was observed with extensive refractory degradation over a period of time. Corrosion was determined to a great extent by dissolution reactions in the interfacial region; alumina dissolution from the refractory resulted in the formation of needle‐like corundum crystallites which transformed to a cohesive network of faceted corundum crystals on extended contact. A number of reaction products containing Mn and Si were also observed.