Alumina aerogel as refractory material

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SUMMARY

The discussion centers on the use of Al2O3 aerogel as insulation for a forge designed for flux crystallization of corundum, specifically ruby and sapphire. The forge must withstand temperatures up to 1400°C (2550°F) and maintain a thermal resistance of at least 1 m²*K/W. The participant expresses concern over the aerogel's performance at high temperatures, referencing a study that indicates potential sintering at temperatures above 1000°C, which could compromise its insulation properties over time. Overall, Al2O3 aerogel is identified as a suitable material for this application, provided that its limitations are carefully considered.

PREREQUISITES
  • Understanding of thermal resistance and insulation materials
  • Familiarity with high-temperature applications and materials science
  • Knowledge of electrical resistance heating systems, specifically MoSi2 heaters
  • Basic principles of gas injection for atmosphere manipulation in furnaces
NEXT STEPS
  • Research the thermal stability of Al2O3 aerogel at temperatures exceeding 1000°C
  • Investigate alternative insulation materials suitable for high-temperature applications
  • Learn about the design and construction of high-temperature forges
  • Explore methods for enhancing the durability of aerogel in extreme conditions
USEFUL FOR

This discussion is beneficial for materials scientists, engineers designing high-temperature furnaces, and hobbyists interested in advanced insulation techniques for metalworking applications.

yrtsimehc
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I'm interested in building a forge, mainly for flux crystallization of corundum (ruby/sapphire), but I want it to be versatile.

General Requirements:
  • Withstand temperatures up to 1400 C (2550 F) for months at a time (crystallization can have very slow kinetics)
  • Walls with a thermal resistance of at least 1 m2*K/W
  • Electrical resistance heaters (MoSi2 or other)
  • Somewhat air-tight to allow for manipulation of furnace atmosphere through gas injection
  • Interior volume of ~8 cubic feet

Al2O3 has good thermal properties for my application, and I'm looking at lining my furnace with several inches of Al2O3 aerogel for use as insulation.

In fact, this is pretty much the only suitable material I've found that will give my furnace walls an acceptable thermal resistance without having to have walls that are 4+ feet thick.

Any thoughts on the suitability of aerogel as forge insulation, or on my plans in general?
 
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Forgot to include this link:

https://e-reports-ext.llnl.gov/pdf/242911.pdf

In this paper, the authors tested the properties of the al2o3 aerogel they synthesized, but not much over 1000 C. They mention that some sintering did occur at the upper bounds, which has me concerned that exposure to very high temperatures would reduce the aergoel's insulation value after several duty cycles.
 

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