From Mg(OH)2 to lightweight closed-pore MgO refractory aggregates: The role of NiO additive

MgO refractory aggregates with high closed porosity were prepared using light-burned MgO and Mg(OH)2 with adding NiO additive. The evolutions of microstructure and pores and their effects on the properties were investigated. The introduction of NiO effectively enhanced growth of MgO grains and transformation of large open pores into small closed ones, attributing to the lattice distortion caused by MgxNi1-xO solid solution formation. Due to the occurrence of more closed pores and lattice distortion, thermal insulation performance was improved significantly. Moreover, the formed circular closed pores and MgxNi1-xO could absorb thermal stress, lower thermal expansion coefficient and induce crack deflection, thus effectively enhancing thermal shock resistance. The specimen with 4.0 wt% NiO showed the best performance, with a median pore diameter of 5.69 μm, closed/apparent porosity of 9.4 %/3.6 %, thermal conductivity of 9.9 W/(m·K) (500 °C), flexural strength of 68.5 MPa, and residual flexural strength of 10.8 MPa after thermal shock.