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Cordierite Mullite Bricks
Cordierite mullite bricks are produced with mullite, erythrite, slate corundum and cordierite as the main raw materials. In order to enhance its properties, ultrafine powder is added to the mixture to strengthen the matrix. The manufacturing process includes kneading, molding, drying and firing at low to medium temperatures. Cordierite mullite bricks are known for their excellent thermal shock resistance (they can withstand 100 water-cooling cycles at 1100°C without cracking) and high-temperature properties (softening point over 1500°C). These bricks are suitable for use in a variety of ceramic industrial environments, such as kiln car surfaces, porous kiln push plates, roller kiln gaskets, ceramic enamel shells and ceramic burners for hot air furnaces.
Cordierite Mullite Refractory Bricks also known as Mullite Cordierite Bricks have unique properties. These bricks are the result of extensive developmental experiments combining the two materials. This combination was designed to address the low toughness and softness of cordierite while enhancing the thermal shock resistance of mullite bricks.
Cordierite is a silicate mineral with a chemical composition of 2MgO-2A12O3-5SiO2. Due to its low coefficient of thermal expansion, good thermal stability, and resistance to thermal shock, cordierite is widely used in automotive exhaust purification equipment, catalyst carriers, heat-resistant coatings, heat exchangers, electronic encapsulants, foam ceramics, and printed circuit boards. In the ceramic industry, it is used in products such as heat exchangers, hot air furnaces, crucibles, slabs and pillar bricks.
The manufacturing process of cordierite involves the use of special ingredients to ensure excellent thermal shock resistance. Refractory products with a high cordierite content can be obtained from refractory raw materials containing specific proportions of MgO, Al2O3 and SiO2. The careful selection of raw materials results in refractory products with high mechanical strength and low coefficients of thermal expansion, which make them suitable for a wide range of ceramic applications. In this process, the firing temperature is crucial to prevent differentiation into mullite and glass phases.
Cordierite mullite bricks have a very small coefficient of thermal expansion (about 1 x 10-6 to 2 x 10-6 °C-1 at 25 to 1000 °C), resulting in excellent thermal shock resistance and chemical stability. However, these bricks have low refractoriness and are prone to decomposition at 1470°C. The combination of cordierite and mullite in the bricks produces microcracks that enhance their thermal shock resistance.
The production process of mullite cordierite kiln furniture requires careful control of the firing temperature and material composition. The goal is to reduce the formation of glassy phases, improve thermal stability, and better control the firing process. Injection molding, high-pressure grouting and mechanical molding are some of the techniques used in the molding process. Key requirements for kiln furniture include high refractoriness, excellent thermal shock resistance and chemical stability. In addition, ambient and high-temperature strength, low heat storage, and precise appearance and dimensions are essential for efficient, high-quality refractory product manufacturing.
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