METAL-IMPREGNATED REFRACTORY AND PRODUCTION THEREOF

Abstract: A metal-impregnated refractory of this invention is excellent in the resistance to spalling and the attack by slag or gas, so that it can be used for making various vessels for treating molten metal. A process for producing the refractory comprises molding a raw material of refractory particles mainly comprising MgO or Al₂O₃ by a suitable method, heating the molded material to form a porous article containing at least 4 % by volume of pores opening outward, and impregnating at least 25 % by volume of said pores with metal or its alloy mainly comprising at least one metal selected from the group consisting of iron, chromium and nickel. The formed refractory can withstand various damages inflicted thereon at higher temperatures, because the metal fills at least those pores which are present in an area ranging from the surface of the refractory to a certain depth thereof, so that it can he used stably for a long period of time.

Description: The present invention relates to a metal-impregnated refractory product for use in various types of molten metal treatment vessels such as a converter, a degassing furnace, and a ladle, and a method of manufacturing the same. The United States Patent US-A 2 792 214 discloses a brick material having improved resistance to penetration by molten slag such as that formed in an open-hearth furnace. The brick comprises a fired mass of refractory material such as a chrome-magnesite mixture. The voids resulting from shaping and firing are filled with a material selected from the group consisting of aluminum, chromium, magnesium, titanium and alloys and oxides thereof. The voids are substantially uniformly impregnated throughout the entire extent of the brick, the brick having a volume percent of remaining voids of from 3 to 15 %. The Japanese publication JP-A 60-46988 discloses a method for impregnating a refractory material by use of centrifugal force. The reference does not disclose metals for impregnation which are oxidation-resistant. Particularly not impregnation with a metal which contains a major portion of Fe and Ni. The French patent publication FR-A 2,283,105 discloses a refractory material impregnated with a metal. The refractory material is based on magnesite and the metal impregnated is at least 70% magnesium, the remainder being aluminum, iron, silicium, chromium and/or calcium. Refractory products used in a high-temperature furnace are brought into contact with a molten slag and a molten metal and subjected to various damages. In particular, lining bricks located in a slag line of vessel are subjected to a significant corrosion by a molten slag (slag attack) within a short time period. In addition, the bricks spall after the repetition of a heating/cooling cycle. Graphite-containing refractory products such as magnesia-carbon (MgO-C) brick and a castable containing metal fibers having an improved spalling resistance have been recently put into practical use. Conventional refractory products improve the slag attack resistance by adding carbon (graphite) in the refractory product or increasing the density of the refractory product, thereby suppressing penetration of a molten slag into the refractory product. Japanese Patent Registration No. 1401778 discloses a product formed by adding a metal such as aluminum in a carbon-containing refractory product so that the aluminum in the refractory product is preferentially oxidized to prevent high-temperature oxidation of carbon. Published Japanese Patent Application No. 57-500788 discloses a composite body formed by adding a powdered metal to an oxide-based ceramic in order to improve an abrasion resistance and toughness of the oxide-based ceramic. Published Japanese Patent Application No. 49-99512 discloses a method of impregnating a metal in a sintered ceramic matrix. The above conventional refractory products, however, have the following problems in terms of improvements in high-temperature characteristics. 1: When the density of a refractory brick is increased, the spalling resistance is generally decreased. Therefore, the brick easily cracks due to thermal stress. 2: A carbon-containing refractory product is significantly damaged at high temperature because the oxide and the carbon contained in the product directly react. Even at low temperature, the graphite is easily oxidized, so that its application with respect to atmosphere and temperature are limited. 3: In a carbon-containing refractory product containing carbon and metal aluminum, the contained metal is oxidized within a short time period. Therefore, since oxidation of carbon cannot be sufficiently suppressed, a reduction in slag attack resistance occurs in an initial stage. In this case, the slag attack resistance means a resistance against damage caused by a molten slag which penetrates into the refractory product along open pores and dissolves the refractory product. An application to a furnace is not taken into consideration for a conventional metal-impregnated ceramic product. An impregnated metal of the ceramic body flows out at a temperature higher than the melting point of the metal or the ceramic body consists of a composition with a low slag attack resistance. The ceramic body is therefore unsuitable for use in a high-temperature furnace. There are open pores (pores) and closed pores (voids) in a refractory product. Generally, properties (e.g. slag attack resistance and spalling resistance) of a refractory brick are largely affected by amounts, shapes, sizes, and distributions of pores and voids. That is, when the porosity is increased, the brick becomes vulnerable to penetration of molten slag. To the contrary, when a total amount of pores and voids is decreased to increase the density of a brick, a spalling resistance is reduced. Therefore, to improve both the slag attack and spalling resistances in conventional bricks, the amount of pores must be decreased while that of voids is increased. However, it is generally difficult to manufacture such a refractory product. The present invention has been made in consideration of the above situation. An object of the present invention is to provide a metal-impregnated refractory product excellent in various high-temperature characteristics, particularly, a slag attack resistance and a gas attack resistance and having a long life, and a method of manufacturing the same. According to the present invention, a method of manufacturing a refractory product is provided as defined in claim 1. Metal-impregnated refractory products are also provided as defined in claims 3 and 4. The present inventors have made extensive studies on a method of improving both a slag attack resistance and a spalling resistance of a refractory brick and succeeded in impregnating various types of metals into various porous refractory products. A metal impregnation ratio, an impregnation depth, stability of an impregnated metal, and the like are affected by size, cell shape, degassing condition, pressurization conditions and preheating temperature of the porous material brick. Especially the shape of pores in the porous material brick is one of important factors having a large effect on the quality of a metal-impregnated refractory product. Therefore, pores contained in the porous material brick must have a shape which allows easy penetration of a molten metal and sufficiently holds the impregnated metal. When a metal is impregnated into the pores of the porous material brick, penetration of a slag into the refractory product is suppressed, and a reaction between the refractory product and the slag is limited in a portion close to the operation surface. Therefore, a dissolving rate of the refractory product into the slag can be decreased, and no damage is caused by structural spalling generated by penetration of the molten slag. In addition, since the thermal conductivity and the fracture breaking energy of the refractory product are increased, the refractory product becomes stronger against thermal spalling than conventional oxide-based refractory products. The properties of the metal-impregnated refractory product of the present invention are affected by factors described in items 1 to 5 below. 1. High-temperature characteristics of the impregnating metal. 2. Stability of the impregnated metal in pores. 3. An impregnation ratio of an impregnated metal. 4. Impregnation conditions. 5. The composition of a base refractory product. The above factors having effects on the properties of the metal-impregnated refractory product will be described below. 1. High-temperature characteristics of impregnating metal The effect of an impregnating metal is largely degraded during the use in a high-temperature furnace unless it is present in the form of a metal. For this reason, the metal must have a high oxidation resistance at high temperature. Even if the metal has a high oxidation resistance, it is slightly oxidized in the vicinity of an operation surface. Therefore, the produced oxide (metal origin) preferably has a high melting point and does not produce any low-melting substance between the oxide and the base oxide (refractory composition). In addition, since an impregnation treatment must be industrially performed, it is difficult to manufacture a metal-impregnated refractory product by using a metal having a melting point higher than 1,800°C. For the above reasons, a metal to be used in the present invention was limited to a metal containing at least one of Fe, Ni, and Cr. 2. Stability of impregnated metal in pores The effect of the metal-impregnated refractory product is largely degraded if an impregnated metal flows out of the pores during the use of the refractory product. The shape of open pores of the brick has a large effect on preventing an outflow of the impregnated metal. A relationship between the pore shape and the stability of the impregnated metal and a method of controlling pores will be described below. 2.1. Relationship between pore shape and stability of impregnated metal An effect of pore size on the ability of holding an impregnated metal will be described below. An impregnated metal in a molten state is held in pores by a capillary force. When the molten metal is to move out from the pores, contact angle on the forward side differs from contact angle on the backward side. A difference is produced in capillary pressures between the forward and backward sides due to this contact angle difference, and the produced pressure difference serves as a moving resistance of the molten metal. This moving resistive force can be a satisfactory holding force when pore diameter range is 10 mm or less, due to wettability, between such refractory systems as Aℓ₂O₃ and MgO systems refractory and such metals as Fe, Cr, and Ni and the surface tension of each metal. If the pore size is too small, however, a metal vapor and an atmospheric gas penetrate into pores containing the impregnated metal and replace the metal, and the metal flows out of the pores. According to an experiment, penetration and replacement of a gas occur when a pore size is 10 µm or less. When the pore size is large, i.e., 4 mm or more, a metal frequently outflows due to a force generated upon movement during the impregnation treatment. Therefore, the pore size is preferably 10 µm to 3 mm. The effect of a pore shape on the impregnated metal holding force will be described below. Figs. 1 to 3 are views showing models of pores 8 in a material 2. A model 1 in Fig. 1 shows an island-like (knot-like) pore 8, in which a knot portion has a size of 10 µm to 3 mm. A model 2 in Fig. 2 shows a tubular pore 8 having a pore size of 10 µm to 3 mm. A model 3 in Fig. 3 shows a tubular pore 8 having a pore size of less than 10 µm. When the models 1 to 3 are compared with one another, the models 1 and 2 do not easily cause gas penetration/replacement (degassing), while the model 3 easily causes the degassing. In addition, the model 1 has a surface energy per unit mass of an impregnated metal lower than that of the model 2 and moves less easily than the model 2 because the surface energy of a metal is increased upon movement. Therefore, the model 1 has an impregnated metal holding force higher than that of the model 2. 2.2. Controlling method for forming pores Conventional refractory products generally have 7 to 20 vol% of pores, and many of them have an average pore size of 10 µm or less. Therefore, in order to use such a conventional refractory product as a porous material body for a metal-impregnated refractory product, pores having a pore size of 10 µm to 3 mm must be formed. As an exception, there is a refractory product originally having an average pore size of 10 µm or more, such as a magnesia-chromium brick. Even in this case, however, pores having a pore size of 10 µm to 3 mm are preferably formed. A method of controlling pores of the porous material body will be described below. 1 ○ Method getting suitable pores by controlling the size of material particles A pore size can be increased by a particle size distribution obtained by removing fine particles from material particles of a porous material. Fig. 4 shows an average pore size as a function of minimum and maximum particle sizes of magnesia bricks burned at 1 750°C using a sintered magnesia clinker having an MgO particle size of 95 wt% as a material. As is apparent from Fig. 4, when the minimum particle size is 44 µm or more, an average pore size of 8 µm or more, i.e., a pore size suitable for metal impregnation is obtained. Therefore, the minimum particle size was set at 50µm or more. As shown in Fig. 4, when the minimum particle size is 80 µm or more, an average pore size of 10 µm or more, i.e., a more preferable pore size is obtained. If the maximum particle size is too large, no sufficient strength is obtained in the porous material body, and a distribution of the impregnated metal becomes nonuniform. Therefore, the maximum particle size is preferably 10 000 µm or less. 2 Method of controlling pores by mixing thermally volume-reducing particles or thermally volume-reducing fibers The pore amount and the pore shape of a brick can be controlled preferably by adding thermally volume-reducing particles or thermally volume-reducing fibers, which cause thermal decomposition or reaction upon heating and a reduction in volume. The raw material can comprise to 50 vol% of such particles or fibers. In this case, the diameter of the thermally volume-reducing particles or fibers is preferably set within the range of 30 to 10 000 µm. The lower limit of the diameter of the particles or fibers is set at 30 µm because pores having pore sizes large enough to stably hold the impregnated metal cannot be obtained if the diameter is smaller than that. On the other hand, the upper limit of the diameter of the particles or fibers is set at 10 000 µm because, if the diameter is larger than that, an average pore size is increased to reduce the compression strength of a formed product to make it difficult to impregnate a metal and to allow an outflow of the molten metal from the pores. In addition, the length of the mixed fibers is preferably set within the range of 1 000 to 30 000 µm (1 to 30 mm) in order to uniformly mix the fibers into the powder material. Various types of organic fibers can be used as the above fibers. However, it is preferred to use a synthetic fiber or a natural fiber which can cause thermal decomposition even at a baking temperature or a drying temperature as comparatively low temperature as well as a burning temperature as high temperature. Examples of these synthetic or natural fibers are hemp, a vinyl fiber, an acrylic fiber, pulp, and a cotton yarn. Fig. 5 shows the porosity of a magnesia brick mixed with hemp having a diameter of 500 µm and a length of 3 mm as an example. As is apparent from Fig. 5, the porosity was increased upon mixing of the hemp, and an average pore size was also increased as the mixing amount was increased. 3 ○ Method of adding metal particles In addition to the control of pores of the brick, the metal diameter obtained after impregnation of a metal can be controlled preferably by mixing 5 to 20 vol% of metal particles having a particle size of 30 to 1 000 µm into the raw material. The lower limit of the particle size of the metal particles is set at 30 µm because, if metal particles having a particle size smaller than that are mixed, the particle size is decreased to be 10 µm or less due to deformation of the metal particles during forming and burning of the brick, resulting in an insufficient force for holding metal particle in pores. On the other hand, the upper limit of the particle size of the metal particles is set at 10 000 because, if the particle size is larger than that, only the metal particles are sometimes removed from matrix, therefore a slag attack rate of matrix accelerates when a slag attack proceeds to expose the metal particles. In addition, the amount of the metal particles is set at 5 to 20 vol% because no satisfactory addition effect can be obtained if the amount is 5 vol% or less and a formed brick cannot acquire satisfactory sintering strength to make it impossible to perform the metal impregnation treatment if the amount exceeds 20 vol%. 3. Impregnation ratio of impregnated metal An impregnated metal is preferably, uniformly distributed in a portion of the refractory product brick to be damaged during the use. Figs. 6 and 7 show a slag penetration depth and a slag attack rate, respectively, obtained by a rotational erosion test for metal-impregnated refractory products formed by impregnating SUS 304 in magnesia bricks (MgO; 95 wt%) having different porosities and metal impregnation ratios. Both the slag penetration depth and the corrosion speed are reduced upon impregnation of 25 vol% of the SUS 304. As is apparent from Figs. 6 and 7, as the metal impregnation ratio is increased, the slag penetration depth and the corrosion speed are decreased. Therefore, the metal impregnation ratio is preferably increased. 4. Metal impregnation conditions A method of impregnating a metal in a brick preferably has the following steps (a) to (f). (a) A heating step for heating a brick up to a temperature of the melting point or higher than a metal to be impregnated. (b) A degassing step for degassing an internal gas of the brick to 13 kPa (100 Torr) or less. (c) A dipping step for dipping the brick in a molten metal bath preferably at a temperature of 1 500°C to 1 670°C. (d) A pressurizing step for pressurizing the brick in the molten metal bath up to a predetermined pressure within the range of an absolute pressure of 0.1 to 10 MPa (1 to 100 kg/cm²). (e) A removing step for removing the brick impregnated with the metal from the molten metal bath. (f) A slow cooling step for slowly cooling the removed brick. The vacuum degree of the above degassing step is set at 13 kPa (100 Torr) because degassing becomes insufficient at a low vacuum degree exceeding 100 Torr and the molten metal is pushed back by an internal residual gas pressure when the applied pressure is released. The applied pressure is set at an absolute pressure of 0.1 to 10 MPa (1 to 100 kg/cm²) because at least 0.1 MPa (1 kg/cm²) is required to impregnate the metal in 25 vol% or more of pores. On the other hand, if the applied pressure is 10 MPa (100 kg/cm²), almost no increase is found in the metal impregnation amount. Fig. 8 is a graph showing check results of a metal penetration depth obtained by variously changing degassing and pressurization conditions, in which the abscissa indicates a pressurization time and the ordinate indicates the metal penetration depth. Referring to Fig. 8, a curve G indicates a result obtained when a brick was degassed in a furnace at a vacuum of 16 kPa (120 Torr) and dipped in a molten metal bath at an atmospheric pressure of 1.0 MPa (10 kg/cm²). A curve H indicates a result obtained when a brick was degassed in a furnace at a vacuum degree of 13 Pa (0.1 Torr) and dipped a molten metal bath at an atmospheric pressure of 1.0 MPa (10 kg/cm²). Note that the temperature of the molten metal bath was about 1 600°C, and a brick of 200-mm cube was dipped in the bath. As is apparent from Fig. 8, when the degassing condition is set at a vacuum of 13 Pa (0.1 Torr), the metal penetration depth reaches a depth of 100 mm or an core after about 10 minutes of a pressurization/dipping treatment. On the contrary, when the degassing condition is set at a vacuum of 16 kPa (120 Torr), only a penetration depth of about 85 mm can be obtained, and an internal residual gas amount after the degassing treatment is left non-impregnated. Therefore, the vacuum degree during the degassing treatment is preferably increased up to 13 Pa (0.1 Torr) or more. 5. Composition of brick The metal-impregnated refractory product according to the present invention is used in a member which is brought into contact directly or indirectly with a molten product or a dry gas. This metal-impregnated refractory product is characterized by impregnating a metal mainly consisting of iron, chromium, nickel in a brick, which is formed of a refractory substance mainly composed of MgO or Aℓ₂O₃ and contains at least 4 vol% of open pores (pores communicating with the surface), at a ratio of 25 vol% or more of the pores. The content of MgO or Aℓ₂O₃ as the main component is preferably 40 wt% or more with respect to the brick before impregnation of the metal. A magnesia system refractory product preferably contains 40 wt% or more of MgO and contains Aℓ₂O₃, Cr₂O₃, ZrO₂, and SiO₂ as other components. An alumina system refractory product preferably contains 60 wt% or more of Aℓ₂O₃ and contains MgO, ZrO₂, and SiO₂ as other components. The brick preferably contains a binder agent or a pore controlling agent (e.g., an organic fiber) in addition to the above components. The operating atmosphere, the slag component, and the like change in accordance with the type of a high-temperature furnace in which the metal-impregnated refractory product is used invention. Therefore, the composition of the brick is important as in the case of conventional refractory products. Some of the experiments which lead to embodiments of the present invention as examples and also comparative examples will be described below. Manufacture and properties of brick Tables 1(1) and 1(2) show manufacture examples of a brick of magnesia system with metal impregnation, and results of an outflow test of impregnated metal. A sintered magnesia clinker containing 98% of MgO was used as a magnesia material, and a bittern was used as a molding binder. A pressure was set at 100 MPa (1 ton/cm²), and the size of the formed block was 150 mm × 100 mm × 300 mm. As a result, pores having a pore size of 10 µm or more could be formed by any of particle size control of removing fine particles having a particle size of 44 µm or less mixing of thermally volume-reducing particles or fibers, and mixing of metal particles. In addition, as the ratio of pores having a pore size of 10 µm or more was increased, an outflow ratio of an impregnated metal in the outflow test at high temperature was decreased. As a result, a slag resistance and an oxidation resistance of the impregnated metal were improved to realize a large metal impregnating effect. The same effects as those of the sintered brick were obtained by a non-sintered brick (Example 12) and a cast-molded brick (Example 13). In the molding of Example 12, a binder or a novolak phenol resin was mixed in raw material. Note that in the erosion test shown in Tables 1(1) and 1(2), a temperature was held at 1 700°C for four hours, and an eroding agent was replaced every 30 minutes. The eroding agent had a composition of 27 wt% of silica sand, 53 wt% of lime, and 20 wt% of mill scale and was replaced in an amount of 1 kg at a time. Tables 2(1) and 2(2) show manufacture examples of a brick of an alumina system containing 96% of Aℓ₂O₃ and a brick of magnesia/chromium system containing 55% of MgO and 32% of Cr₂O₃ with metal impregnation. As is the case with the brick of magnesia system porous material body, the metal impregnating effect was enhanced as the ratio of pores having a pore size of 10µm or more was increased. The porous material brick of magnesia/chromia system provided a high ratio of pores having a pore size of 10 µm or more and good results even in Example 18 in which the porous material body was manufactured by the same method as that of a conventional refractory product. Note that in the erosion test shown in Tables 2(1) and 2(2), a temperature was held at 1 700°C for four hours, and an eroding agent was replaced every 30 minutes. The eroding agent had a composition of 32 wt% of silica sand, 48 wt% of lime, and 20 wt% of mill scale and was replaced in an amount of 1 kg at a time. Tables 3(1) and 3(2) show a change in impregnation amount obtained in accordance with the vacuum and an applied pressure when Fe-18Cr was impregnated in a brick of magnesia system Similar to that in said Example 3. When the vacuum degree was 13 kPa (100 Torr) or less, the metal could be impregnated to the core of a porous material body. To obtain a better impregnated refractory product, the vacuum degree is preferably 1 Torr or less. Even when the applied pressure was increased up to 10 MPa (100 kg/cm²) or more, no large increase is found in the impregnation amount. Tables 4(1), 4(2), and 4(3) show results obtained by manufacturing metal-impregnated refractory products consisting of magnesia, spinel, magnesia/chromium, magnesia/dolomite and performing tests using a actual converter and a stainless smelting furnace. Better results than those obtained using conventional MgO-C bricks could be obtained in any of the wall and the tapping member of the converter and the wall of the stainless smelting furnace. Tables 5(1) and 5(2) and Tables 6(1) and 6(2) show results of actual tests using a molten iron ladle, a molten steel ladle, and an RH degassing smelting furnace. A large effect was found since the corrosion speed of the metal-impregnated refractory product was small. According to the metal-impregnated refractory product of the present invention, since pores contained in the refractory product are filled with a metal, high slag attack resistance, gas attack resistance, spalling resistance, and corrosion resistance can be obtained. Therefore, when this metal-impregnated refractory product is used in slag lines and the like of various types of metal smelting furnaces and molten metal vessels, the life of the furnace or vessel can be largely prolonged as a whole. In addition, a maintenance cost can be largely reduced by using the metal-impregnated refractory product in expendable supplies subjected to a significant damage by a tapped molten steel, such as the tapping hole of a converter. Especially when a porous material brick is formed by adding various types of cell controlling agent in a material body so as to control pores contained in the brick in a desired state, a metal can be impregnated more easily. By controlling pores in a desired state in this manner, a metal can be impregnated in a central portion of a large porous molded body to enable manufacture of a large metal-impregnated brick. Large metal-impregnated bricks can be used as linings in, e.g., a converter and a degassing furnace. In addition, large bricks can be used as a molten metal contact block of a ladle and the inner wall of a slag line. Furthermore, large bricks can be used in a portion of an apparatus subjected to a high-temperature atmosphere, such as a coal liquefying gas pipe. By selecting pore control conditions and molten metal impregnation conditions (e.g., an applied pressure and a heating temperature), a metal-impregnated brick having a high impregnation amount can be obtained. Since the metal-impregnated brick having a high impregnation has various characteristics not found in conventional bricks, various types of structures can be constructed using good mechanical properties and workability. In addition, the metal-impregnated brick having a high impregnation can be used as a functional material as well as a structural material. For example, the brick can be used as an ultrasonic medium for transmitting an ultrasonic wave directly to a high-temperature molten product.

Claims: A method of manufacturing a metal-impregnated refractory product, comprising: (a) heating a porous material body, which is formed of a refractory substance comprising MgO or Al₂O₃ and which contains at least 4% by volume pores open to the surface, up to a temperature higher than the melting point of a metal to be impregnated into the open pores, said metal being selected from the group consisting of at least one of iron, chromium and nickel, or an alloy containing one of said metals, wherein the total amount of iron and nickel in said metal or alloy is not less than 50% by weight; (b) removing gas contained in said heated porous material body from step (a); (c) dipping said degassed porous material body from step (b) in a molten metal bath of said metal to be impregnated; (d) pressurizing the molten metal in said molten metal bath at an absolute pressure of 0.1 to 10 MPa (1 to 100 kg/cm²) to allow the molten metal to penetrate into the pores of said porous material body; (e) removing the formed product from said molten metal bath; and (f) slowly cooling said formed product. A method according to claim 1, wherein the molten metal in the dipping step (c) has a temperature within the range of 1,500 to 1,670°C. A metal-impregnated refractory product suitable for use in direct or indirect contact with a molten material, said refractory product comprising a MgO-based porous material impregnated with at least one metal selected from the group consisting of iron, chromium and nickel or an alloy containing at least one of said metals, wherein the total amount of iron and nickel in said metal or alloy is not less than 50% by weight, said porous material prior to being impregnated having at least 4% by volume of pores open to the surface, wherein more than 25% of said open pores are impregnated with said metal or alloy; said MgO-based porous material being sintered and containing at least one component selected from the group consisting of Cr₂O₃, Al₂O₃, ZrO₂ and SiO₂; or said MgO-based porous material being sintered and containing at least one component selected from the group consisting of CaO, ZrO₂ and SiO₂; wherein said molten metal is maintained within said refractory product even if subjected to a temperature high enough to cause said impregnated metal to be at least partially melted. A metal-impregnated refractory product suitable for use in direct or indirect contact with a molten material, said refractory product comprising an Al₂O₃-based porous material impregnated with at least one metal selected from the group consisting of iron, chromium and nickel or an alloy containing at least one of said metals, wherein the total amount of iron and nickel in said metal or alloy is not less than 50% by weight, said porous material prior to being impregnated having at least 4% by volume of pores open to the surface wherein more than 25% of said open pores are impregnated with said metal or alloy; said Al₂O₃-based porous material contains at least one component selected from the group consisting of MgO, ZrO₂ and SiO₂; wherein said molten metal is maintained within said refractory product even if subjected to a temperature high enough to cause said impregnated metal to be at least partially melted. A metal-impregnated refractory product according to claim 3 or 4, characterized in that said metal or alloy is impregnated into said pores at a temperature within the range of 1,500 to 1,670°C. A metal-impregnated refractory product according to one of the preceding claims, wherein said porous material prior to being impregnated contains 5 to 20 vol.% of metal particles having a particle size of range of 30 to 3,000 µm. A metal-impregnated refractory product according to one of the preceding claims, wherein said porous material is formed of refractory particles having a particle size of range of 44 to 10,000 µm as a raw material. A metal-impregnated product according to claim 7, wherein 5 to 50 vol.% of volume-reducing particles or fibers are added to said raw refractory material, said particles or fibers reducing in volume by thermal decomposition or reaction upon heating and said particles or fibers having a diameter in the range of 30 to 3,000 µm. A metal-impregnated product according to claim 8, wherein said volume-reducing fibers have a length in the range of 1,000 to 30,000 µm.

Inventors: IIYAMA MAKOTO, KOBAYASHI MOTONOBU, MURAKAMI NOBORU, NUMATA NORIJI, TANABE HARUYOSHI, IIYAMA, MAKOTO, KOBAYASHI, MOTONOBU, MURAKAMI, NOBORU, NUMATA, NORIJI, TANABE, HARUYOSHI
Applicants: NIPPON KOKAN KK, NKK CORPORATION
Application year: 1990
Main classification: C04B41
IPC codes: C04B41, C04B38