Comprehensive Quality Assessment of Refractory Materials Used in Aluminum Production

Corrosion of refractory materials in NaCl-KCl melts is a major issue affecting the service life of linings in aluminum metallurgy, where these salts serve as the basis for covering and refining mixtures. The aim of this study was to comprehensively evaluate the corrosion resistance of alumina-silicate refractory materials (ASRM) with a high SiO₂/Al₂O₃ ratio in contact with melts of varying NaCl-KCl ratios. Static crucible corrosion tests were conducted in accordance with the technical specification CEN/TS 15418:2006. Macro- and microscopic analysis, chemical analysis (AAS), and semi-quantitative EDX analysis enabled detailed monitoring of the depth of melt infiltration, microstructural changes, and element distribution within the material. The results demonstrated that as the NaCl content in the melt increased, there was a significant rise in both the depth of infiltration and the degree of material degradation. A linear regression model confirmed a very strong positive correlation between NaCl content and the extent of damage (R² = 0.967). Chemical analysis revealed that the silicon content decreases in the infiltrated zone, while aluminum remains stable, indicating superior corrosion resistance of Al₂O₃ compared to SiO₂. EDX analysis also confirmed increased concentrations of sodium and chlorine in the infiltrated areas, complementing the AAS results and providing more precise mapping of the distribution of corrosion products within the material structure. These findings provide a quantitative basis for optimizing the composition of refractory materials and designing protective strategies to extend their service life under the aggressive operating conditions of aluminum production.