The bauxite residue (BR) is the solid waste of largest generation by the aluminum industry, with a generation estimated in 10 million ton/year in Brazil. Its high alkalinity demands elevated costs to store it safely. Due to the high content of Al2O3 and Fe2O3 in BR, the present study evaluated its application for the synthesis of iron rich sulfobelite clinkers. Because of its composition, the cement made with this clinker presents environmental (30% to 62% reduction of CO2-equivalent emission), economic and even technical advantages over Portland cements. Formulations containing: limestone, gypsum, BR and clay, were fired at 1230°C to synthesize the clinkers. Variations in BR and clay content were studied to obtain three formulations, F-15, F-18 and F-21, of different Al2O3/Fe2O3 ratio values. Cements containing more than 10.5 wt-% of BR achieved mechanical resistance comparable to Portland cements (CP-II-Z32 and CP-V-ARI) for 7 and 28 days of curing age.

Thermal shock is one of the most severe conditions to which a refractory lining can be subjected to during its industrial application. Thus, there are several methods available for testing thermal shock damage resistance of refractories. Among them, a very common method is the quench test, which consists of quenching a hot refractory bar into water. After that a retained mechanical property is determined. Considering this, the aim of the work herein is to compare the thermal shock damage resistance between two specimen sizes among several materials. The dimensions 150 mm × 25 mm × 25 mm and 160 mm × 40 mm × 40 mm were used. The small bars are generally used for mechanical characterization in the refractory field (recommended by ASTM C1171-05). The large bars, on the other hand, are a requirement of DIN 196-1, which regards procedures for testing cement materials. Experimental results have indicated that the thermal shock damage is bigger for the large bars, as predicted by theoretical aspects. Although the size difference between the specimens was not so big, it was possible to observe the size effect using a statistical treatment. Five different castable formulations, of which three contained eutectic aggregates, were tested. The highest variation found in thermal shock damage resistance because of the size was about 15%.

Calcium aluminate cements (CAC) were prepared using the sonochemical process, followed by heat treatment. A study was made of the action of ultrasonic waves and the influence of thermal treatment conditions on two initial molar compositions of 1:1 and 1:2 of calcia:alumina. The aqueous suspension containing the raw materials (A-50 alumina and CaO) was subjected to an ultrasonic bath, followed by drying and burning at 1000, 1200 and 1300 ºC. These cements were characterized by SEM, XRD and the mechanical strength was evaluated by splitting tensile tests, using commercial cement as a reference. Furthermore, the phases were semi-quantified using the Rietveld method. The results show that hydration and sonochemical action increased the reactivity of the raw materials during firing and that phase formation is dependent on the thermal treatment conditions. The CAC cements were obtained at temperatures at least 200 ºC lower than those used in conventional methods, indicating the potential of this route of synthesis.

Double-torsion tests were carried out to ascertain whether a thin test specimen would affect the results of this test. The tests involved two test specimen sizes, one with a thickness five-fold greater than the particle size of the material and the other with a three-fold greater thickness. The width of both test specimens was ten times that of their thickness and their length was double their width. The material utilized was an alumina-based refractory castable without cement. It is important to ascertain the influence of the thickness of double-torsion test specimens when materials with a coarse microstructure are involved. Otherwise, test specimens would have to be very large, rendering the experimental procedure difficult, as in the case of the size of sintering furnaces and the size of accessories for the test. This study shows that test specimens with lower thicknesses are representative when one analyzes the calibration curve of the compliance, the length of the crack at which the break occurred (critical crack length), and the shapes of the R-curve and of the load (P) vs. displacement curves. However, the analysis of the mean values of R (R), obtained by the arithmetic average of the R values in the section of stable crack propagation and the total fracture energy (γwof), showed that these values are dependent on the size of the test specimens, indicating that this subject deserves further investigation.

Double-torsion tests were carried out on a commercial ceramic floor tile to verify whether this test is suitable for determining the R-curve of ceramics. The instantaneous crack length was obtained by means of compliance calibration, and it was found that the experimental compliance underestimates the real crack length. The load vs. displacement curves were also found to drop after maximum loading, causing the stress intensity factor to decline. The R-curves were calculated by two methods: linear elastic fracture mechanics and the energetic method. It was obtained that the average values of crack resistance, R, and the double of the work of fracture, 2 <FONT FACE=Symbol>× g</FONT>wof, did not depend on notch length, a0, which is a highly relevant finding, indicating that these parameters were less dependent on the test specimen's geometry. The proposal was to use small notches, which produce long stable crack propagation paths that in turn are particularly important in the case of coarse microstructures.

The purpose of this work is to show the correlation between the fractal dimension, D, and mechanical properties such as work of fracture, gammawof, and fracture toughness, K Ic. Alumina-mullite-zirconia composites were characterized by the slit-island method, SIM, to obtain values of D and its fractional part, D*. The fracture surface roughness was also evaluated using a cyclic voltametric method. It will be shown that there is a positive experimental dependency of gammawof on D* and that there is not an evident correlation between K Ic and D*.

The fractals theory has been increasingly applied in the field of materials science and engineering. Models of fractal lines and surfaces have been generated to describe the microstructural features of materials. Special interest is placed upon a description of the fracture surface based on a fractal geometry in order to understand the crack path in materials. Several papers have demonstrated the relationship between the fractal dimension of a fracture surface and the values of roughness and fracture toughness. In this work an extension of the theory of fractals for ceramic materials is proposed, to which the crack deflection toughening mechanism is thought to be related. In order to accomplish this objective, a review describing the concept of fractals and its relationship with the fracture toughness is presented. In the following part, a correlation between fractal dimension, total energy of fracture and the average resistance to crack propagation is proposed; all these parameters being dependent on the history and on the complexity of crack propagation path.