A new strategy to prepare MLG-SiCw/SiCp composites via three-roll milling exfoliation and catalytical-conversion for advanced refractories.

Cost-effective decarbonization and structural strengthening of carbon-containing refractory materials are crucial for the development of low-carbon steel (LCS) and ultra-low-carbon steel (ULCS) technologies. In this study, a carbonaceous-ceramic reinforcement assembly structure composed of multilayer graphenes and silicon carbide whiskers/particles (MLGs-SiC w /SiC p) has been successfully designed and fabricated. By employing three-roll milling (TRM) for low-cost exfoliation of expanded graphite (EG) into MLGs in a phenolic resin (PF) medium, we optimized the exfoliation cycles to fine-tune the morphology of MLGs. Subsequently, the catalytical solid-state conversion of PF/MLGs reacting with Si into SiC w /SiC p at 1400 °C, under varying C/Si molar ratios and catalyst contents, not only retained the structural integrity of MLGs but also embedded them within a novel SiC w /SiC p composite matrix. Our research elucidates the catalytic conversion mechanism, underscoring the significant role of nickel catalysts in promoting efficient SiC conversion. This work offers a promising pathway for developing high-performance, economical, low-carbon refractories. [ABSTRACT FROM AUTHOR]