Microsilica or MgO grain size: Which one mostly affects the in situ spinel refractory castable expansion?

Microsilica is commonly added to alumina–magnesia castables to counterbalance the in situ spinel expansion. This effect is attained by the generation of a low-melting temperature phase, which also affects the expansive reaction kinetics. Additionally, the MgAl2O4 formation depends on the grain size of the reactants. The use of coarse magnesia grains results in lower Mg2+ dissolution and could lead, at 1500 °C, to forsterite development (Mg2SiO4). For finer MgO, silica was detected at the edge of the spinel grains. Considering these aspects, this work evaluated the effect of microsilica content for different magnesia grain sizes (<45 or <100 μm). Due to a faster spinel formation for the fine MgO source, microsilica counterbalanced the MgAl2O4 expansion. Conversely, for the coarser MgO, silica increased the Mg2+ dissolution, speeding up the spinel formation and expansion. Therefore, microsilica presented opposite roles, pointing out that it does not always counterbalance the spinel expansion. This work also indicated the need for a systemic approach for the expanding design of alumina–magnesia refractory castables.