Alumina is one of the most used raw material in refractory applications. The steel industry is a big consumer of alumina-based materials due to their high mechanical strengths, resistance to thermal shock and chemical corrosion. The design of a specific microstructure is essential to adapt the properties towards a higher resistance against thermal stresses and increasingly demanding environments in service. The key features of the raw materials can be tailored to the achievement of a more thermomechanically sustainable solution.

Within the context of the European CESAREF (Concerted European Action on Sustainable Applications of REFractories) project, this study summarizes first results obtained with specific alumina-based raw materials. Special focus is given to the thermal cycling and shock resistance which is traditionally relatively low for large grain sized or non-spherical shaped alumina-based castables and often their life limiting factor. The link between the microstructure design and the thermal shock resistance will be investigated and more particularly the bonding between the fine components and the aggregates contained in the castable formulation. Moreover, new tools of characterization are used for a better monitoring of the thermomechanical behavior of the refractory materials tested at high temperature.