Refractories

Effect of fused magnesia on properties of anorthite-spinel insulation refractories

Wang Shizhen, Han Bing-qiang, Tan Dan, Wei Yaowu, Yan Wen, Li Nan

2026, (1): 1-7. doi：10.3969/j.issn.1001-1935.2026.01.001

To optimize the phase composition and microstructure of porous anorthite-spinel thermal insulation refractories,thereby enhancing their physical properties,porous anorthite-spinel thermal insulation refractories were prepared via a direct foaming method at 1 200 ℃ for 3 h,using corundum dust,quartz sand,limestone powder and fused magnesia as the main raw materials.The effects of the fused magnesia addition (0,2%,4% and 7%,by mass,respectively) on the microstructure and properties of the resultant materials were investigated.The results show that:(1)the addition of fused magnesia significantly optimizes the phase composition and pore structure of the anorthite-spinel thermal insulation refractories;fused magnesia reacts in-situ with Al₂O₃ to form spinel,thus constructing a ternary composite pore-wall structure composed of anorthite,corundum and spinel;benefiting from the pinning effect of spinel,the pore-wall morphology transforms from an isolated island-like structure into a uniform network structure;(2)with the fused magnesia addition increasing from 2% to 7%,the bulk density of the samples first increases and then decreases,the total porosity first decreases slightly and then increases sharply;the linear expansion rate increases continuously;the cold compressive strength remains basically unchanged at first and then increases sharply,and the thermal conductivity decreases gradually;(3)the sample with 7% fused magnesia exhibits the optimal comprehensive performance.

Thermal stress analysis of ceramsite layer at bottom of molten salt tanks based on discrete elements

Huang Yao, Liu Yuanjiong, Zhu Hailong, Li Yuanbing, Hu Liang

2026, (1): 8-12. doi：10.3969/j.issn.1001-1935.2026.01.002

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For the ceramsite backfill layer at the bottom of the molten salt tank,a corresponding particle simulation model was established based on the EDEM discrete element software platform to simulate the compaction and backfilling process of the ceramsite layer as well as the full-tank operation condition.The research focused on examining the mechanical effects of three pre-compaction processes (natural stacking,single pre-compaction,and 8-stage segmented pre-compaction) on the compression deformation and stress distribution in the ceramsite layer,while also analyzed the influence of different particle size ranges (5-10,10-15,and 15-20 mm) on the heat transfer behavior.The results show that:(1) under an 8-stage segmented pre-compaction process with a layer height of 1.6 m,particle sizes ranging from 5 to 20 mm,and a heavy-tank load of 50 000 t,the maximum internal stress of the ceramsite ranges from 8.0 to 14.4 MPa,with uniform pressure distribution and an overall settlement of 20.44 mm;(2) as the particle size increases,the heat transfer distance gradually extends while the average heat flux decreases;this indicates that smaller particles provide better thermal insulation,with a heat transfer distance of 185.73 mm and an average heat flux of 0.49 W·m^-2 over 50 h,whereas larger particles exhibit higher thermal conductivity and poorer insulation,allowing heat to dissipate more readily,with a corresponding heat transfer distance of 195.65 mm and an average heat flux of 2.31 W·m^-2.

Preparation of lightweight periclase-hercynite refractories with lightweight magnesia for firing zone of cement kilns

Sun Gege, Li Guohua, Deng Shudan, Tian Lin

2026, (1): 13-18. doi：10.3969/j.issn.1001-1935.2026.01.003

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To improve the thermal efficiency of cement kilns,lightweight periclase-hercynite refractories for cement kilns were prepared using self-made lightweight magnesia,sintered magnesia,and hercynite as raw materials.The effects of replacing 3-1 mm sintered magnesia with equal mass fractions (0,10%,20%,30%,and 40%) of self-made lightweight magnesia on the bulk density,apparent porosity,cold compressive strength,thermal shock resistance,refractoriness under load (RUL),and cement clinker corrosion resistance of the samples were investigated.The results show that:(1)as the lightweight magnesia addition increases,the bulk density of the samples decreases and the apparent porosity increases;(2)lightweight magnesia can form an interlocking interface with the matrix,thereby enhancing the cold compressive strength and improving the thermal shock resistance of the samples;(3)the appropriate addition of lightweight magnesia improves the cement clinker corrosion resistance of the samples and reduces the corroded area;(4)when the lightweight magnesia addition reaches 20%,the samples exhibit the optimal comprehensive performance,with the bulk density of 2.78 g·cm^-3,apparent porosity of 21.9%,cold compressive strength of 76.2 MPa,and refractoriness under load exceeding 1 700 ℃.

Action mechanism of insulation time in microwave-assisted borothermal/carbothermal synthesis of TiB₂ powder

Chang Shilun, Liu Zhenyang, Wang Xingguo, Li Xin, Zhang Zhaolei, Qiao Jia, Chen Bin

2026, (1): 19-24. doi：10.3969/j.issn.1001-1935.2026.01.004

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To clarify the regulatory mechanism of the insulation time on the synthesis process of titanium diboride (TiB₂) powder in microwave fields,this study took the TiO₂-B₄C-C system as the research object and adopted a microwave-assisted borothermal/carbothermal coupled reduction process to systematically investigate the evolution of the phase composition,morphology and particle size distribution of the products with different insulation time (10,20,30,and 40 min) at 1 450 ℃,thereby revealing the crystal growth mechanism of TiB₂.The results show that:when the insulation time is 10 min,an intermediate reaction process involving TiO₂ and B₄C occurs in the system,resulting in the formation of byproducts TiC and B₂O₃;when the insulation time is extended to 20 min,the reactions of TiC,B₂O₃ and C complete,obtaining pure-phase TiB₂ powder;when the insulation time exceeds 30 min,the microwave non-thermal effect is significantly enhanced,inducing abnormal grain growth and formation of sintering necks.The optimal process parameters are insulation at 1 450 ℃ for 20 min,obtaining submicron TiB₂ powder with d₅₀ of 0.32 μm,which has clear grain boundaries and regular hexagonal structures.

Process optimization of zirconia ceramics via photocuring 3D printing

Shi Yingtong, Zheng Wenwen, Xie Hehan, Liu Peng, Liu Ziyu, Yang Xianfeng

2026, (1): 25-30. doi：10.3969/j.issn.1001-1935.2026.01.005

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To address the poor dispersibility of sub-micron zirconia powder and the severe warpage that occurs during photocuring,zirconia ceramics were fabricated via photocuring 3D printing,using high-purity sub-micron zirconia powder (4Y-TZP) as the raw material,a blend of trimethylolpropane triacrylate (TMPTA),1,6-hexanediol diacrylate (HDDA) and polyethylene glycol diacrylate (PEG400DA) as the composite photosensitive resin system,bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide as the photoinitiator,and 3-glycidoxypropyltrimethoxysilane (KH560),castor oil,and polymeric phosphate anionic dispersant (BYK-111) as dispersants,respectively.The effects of the photosensitive resin formulation,dispersant type,solid content,and photocuring molding process parameters on the rheological properties and suspension stability of the zirconia ceramic slurry,as well as the quality of green bodies were investigated systematically.The results indicate that:(1)when the dispersant KH560 addition is 0.5% of the zirconia powder mass,TMPTA accounts for 36% of the total addition of the composite photosensitive resin,and the solid content is 36 vol%,the prepared zirconia ceramic slurry exhibits excellent rheological properties and suspension stability;(2)under the printing parameters of exposure power of 1 230 mW·cm^-2,scanning speed of 2 000 mm·s^-1,and curing times of 2,the monolayer curing depth can reach 0.095 mm with high forming precision;after debinding at 600 ℃ in a nitrogen atmosphere and subsequent sintering at 1 550 ℃,dense zirconia ceramics can be obtained,with the apparent density of 5.80 g·cm^-3 and flexural strength of 641 MPa.

Effects of nano-alumina and heat treatment temperature on performance of MgO ceramic filters

Zhang Yusheng, Huang Ao, Zou Yongshun

2026, (1): 31-37. doi：10.3969/j.issn.1001-1935.2026.01.006

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To improve their mechanical properties,MgO ceramic filters with porous skeleton structures were prepared by the organic foam impregnation method using microporous MgO powder as the raw material.The effects of the second-phase nano-alumina additions (0,3%,6%,9%,and 12%,by mass) and heat treatment temperatures (1 450,1 500,1 550,and 1 600 ℃) on the physical properties,phase composition,microstructure and mechanical properties of the ceramic filters were investigated.The results show that:the introduction of nano-alumina leads to the in-situ formation of magnesium aluminate spinel among the grains,which improves the grain bonding strength,reduces the apparent porosity,increases the bulk density and improves the cold compressive strength.However,when the nano-alumina addition exceeds 6%,excessive spinel among the grains hinders the direct bonding of MgO grains,thus reducing the cold compressive strength.The raise in the heat treatment temperature increases the solid solubility of Al₂O₃ in MgO,thereby promoting sintering,increasing the relative density,and enhancing the cold compressive strength.With the nano-alumina addition of 6% and heat treatment temperature of 1 600 ℃,the filter exhibits the maximum cold compressive strength of 1.42 MPa,the apparent porosity of 81.5%,and the bulk density of 0.66 g·cm^-3.

Effect of Carbores P addition on properties of Ti₃AlC₂ ceramic filters

Li Fei, Xiao Junli, Zhou Hui, Wei Yao-wu, Yan Wen, Li Nan, Chen Junfeng

2026, (1): 38-42. doi：10.3969/j.issn.1001-1935.2026.01.007

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To expand the application of Ti₃AlC₂ materials,Ti₃AlC₂ ceramic filters were prepared via the polymer sponge replica technique using Ti₃AlC₂ powder as the main raw material.The influence of the Carbores P additions (0-30%,by mass) on the properties of the Ti₃AlC₂ ceramic filters was studied.The results indicate that the main phase of the ceramic filters is Ti₃AlC₂ after the heat treatment at 1 100 ℃ in a carbon embedded atmosphere.However,a portion of Ti₃AlC₂ reacts with CO to form TiC and α-Al₂O₃.Furthermore,with the Carbores P addition rising,the viscosity of slurry for preparing the ceramic filters increases,thus increasing the strut diameter of the ceramic filters and reducing defects.The Carbores P addition alters the bonding mode between Ti₃AlC₂ particles after heat treatment,resulting in tighter bonding and enhanced cold compressive strength of the ceramic filters.The sample with 20% Carbores P achieves cold compressive strength of 0.20 MPa.A further increase in the Carbores P addition causes structural collapse of the ceramic filters after the heat treatment at 1 100 ℃.This is attributed to the volume shrinkage of the ceramic filters during the thermal decomposition of Carbores P,which ultimately leads to structural instability.The sample with 20% Carbores P exhibits the optimal mechanical properties.

Effect of silane coupling agent addition on performance of anti-corrosion coatings for ladles

Song Bo, Tian Lin, Tian Chao, Li Guohua, Jiang Yuhan, Ding Yunkai

2026, (1): 43-47. doi：10.3969/j.issn.1001-1935.2026.01.008

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In response to the carbon-free requirements of ladle refractories,a coating slurry was prepared using calcined α-Al₂O₃ powder and yttrium-stabilized zirconia as coating fillers and silane coupling agent (KH-560) as a dispersant,with the addition of a magnesia-aluminia binder.The slurry was brushed onto the surface of a corundum-magnesium aluminate spinel substrate with sizes of 40 mm×40 mm×10 mm,and the coated sample was obtained after the heat treatment at 1 600 ℃ for 1 h.The effects of the KH-560 additions (0,0.5%,1%,1.5%,2%,2.5%,and 3% of the coating filler mass) on the slurry properties and the corrosion resistance of the coating were investigated.The results show that:(1)at room temperature,KH-560 dehydrates and condenses with the hydroxylated Al₂O₃ surface to form a uniform adsorption layer,whose steric hindrance effect reduces the surface tension and viscosity of the slurry,significantly improving its stability;(2)after the heat treatment at 1 600 ℃,mullite is generated by the chemical bonding of KH-560 and Al₂O₃,strengthening the bonding strength between the coating and the substrate;(3)the slag corrosion resistance test shows that,compared with the coated sample without KH-560,the aggregate edges at the corrosion interface of the sample with 1% KH-560 remain intact,the matrix shows no liquid-phase infiltration,and the corrosion index is reduced by 69.8%;(4)the optimal KH-560 addition is 1%.

Micro-nano pore control and properties of thermal insulation carbon fiber composites

Chen Jialiang, Ding Jun, Luo Yixin, Liu Zhenglong, Yu Chao, Zhu Qingyou, Deng Chengji

2026, (1): 48-53. doi：10.3969/j.issn.1001-1935.2026.01.009

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To achieve efficient thermal insulation of carbon fiber composites,a porous structure system was constructed through the solvent-induced phase separation strategy using T300 carbon fiber prepregs as the reinforcement and epoxy resin as the matrix.Isopropyl alcohol was used as the pore-forming agent and the gradient design of the porosity in the carbon fiber composites was achieved by regulating its additions (0,10%,20% and 30%,by mass).The coupling mechanism of the pore structure evolution on the mechanical and thermal insulation properties of the materials was explored.The results show that:as the isopropyl alcohol addition increases from 0 to 30%,the porosity of the composites increases from 0.71% to 2.14%,accompanied by an increase in the pore number and size,the pore morphology evolves from point-like defects to circular defects,while the mechanical properties show a controllable degradation trend;meanwhile,the thermal insulation performance shows a gradually increasing trend.When the isopropyl alcohol addition is 10%,the material exhibits a porosity of 1.12%,achieving the minimal reduction in the mechanical properties and relatively optimal thermal insulation performance.

Effect of coal gangue powder addition on prepared porous magnesia aggregates from magnesite tailings

Wang Qianqian, Zan Wenyu, Ma Beiyue, Yuan Xiaozhou, Lan Zhipeng, Yu Jingkun

2026, (1): 54-58. doi：10.3969/j.issn.1001-1935.2026.01.010

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To enhance the resource utilization of magnesite tailings and reduce the production cost of magnesia-based refractories,porous MgO-Mg₂SiO₄-MgAl₂O₄ aggregates were synthesized in-situ using magnesite tailings and coal gangue powder as raw materials,firing at 1 300 ℃ for 4 h.The effects of the coal gangue powder additions (0,10%,20%,30%,and 40%,by mass) on the phase composition,microstructure,bulk density,apparent porosity,cold crushing strength,and thermal shock resistance of the specimens were investigated.The results show that:(1)with the increase of the coal gangue powder addition,the linear shrinkage decreases the specimens first decrease and then increase decreases,the apparent porosity decreases,the bulk density and the cold crushing strength increase,and the thermal shock resistance first increases and then declines;(2)when the coal gangue powder addition is 30%,the specimen primarily consists of the crystalline phases of MgO,Mg₂SiO₄,and MgAl₂O₄,showing the optimal comprehensive performance:the linear shrinkage of 12.7%,the volume shrinkage of 30.5%,the apparent porosity of 43.4%,the bulk density of 1.81 g·cm^-3,the cold crushing strength of 56.0 MPa,and the crushing strength retention ratio of 83.3% after 3 thermal shocks.

Effect of TiN_x on properties of uncooled corundum-based slide rail materials for steel rolling heating furnaces

Qiao Lina

2026, (1): 59-64. doi：10.3969/j.issn.1001-1935.2026.01.011

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To improve the service life of uncooled corundum-based slide rail materials for steel rolling heating furnaces,TiN_x-Al₂O₃ materials were prepared with white corundum as the main raw material,and non-stoichiometric TiN_x(x=0.3,0.4,and 0.5) as the binder by spark plasma sintering at 1 350,1 400,1 450,1 500,and 1 550 ℃ for 15 h.The effects of the TiN_x additions (15%,20%,25%,30%,and 35%,by volume) on the relative density,cold compressive strength,wear resistance,refractoriness under load,thermal shock resistance,iron sensitivity,and corrosion resistance against iron oxide slag of the materials were investigated,and the results were compared with those of SiC-Al₂O₃ composites.The results show that:(1)when the heat treatment temperature is 1 450 ℃,the relative density initially increases and then stabilizes as the TiN_x addition increases;(2)when the TiN_x addition is 30%,with the increasing heat treatment temperature,the relative density,cold compressive strength,and wear loss initially increase and then stabilize,the refractoriness under load keeps at 1 800-1 900 ℃,while the number of thermal shock resistance cycles generally shows a declining trend;(3)under simulated working conditions of a steel rolling heating furnace (1 300 ℃,unsealed),the mass of the samples initially increases and then stabilizes with the prolongation of the holding time,and the iron oxide slag penetration depth is between 0.02 and 0.04 mm;(4)comprehensively considering,the samples with 30% TiN_0.4 heat treated at 1 450 ℃ exhibits superior mechanical properties and thermal stability compared to silicon carbide-corundum composites.

Effects of anhydrous borax on properties and mircostructure of Al₂O₃-C composites

Wu Song, Wei Longjie, Wang Jianzhu, Chen Ji, Yuan Yuhui, Liu Cheng

2026, (1): 65-68. doi：10.3969/j.issn.1001-1935.2026.01.012

Abstract ( ) PDF (1740KB)( )

Adding low-melting point phases to Al₂O₃-C composites is of great significance for improving their properties and microstructure.Using brown corundum,alumina powder,and flake graphite as the main raw materials,phenolic resin as the binder,and adding different amounts (0,1%,2%,3%,4%,by mass) of anhydrous borax,the mixture was prepared by mixing with a high-speed counter-current granulator.The resulting mixture was shaped in a cold isostatic press,dried at 250 ℃,and then fired at 1 000 ℃ under a carbon-embedded atmosphere to prepare Al₂O₃-C composite samples.The effects of the anhydrous borax addition on the properties and microstructure of the Al₂O₃-C composites were investigated.The results show that:with the anhydrous borax addition increasing,the apparent porosity of the samples decreases significantly,while the bulk density increases slightly.For the samples containing anhydrous borax,the boundaries between fine powder particles become blurred,and part of the pores between fine powders are filled by the melted anhydrous borax,leading to the significant reduction in porosity,a notable enhancement of cold modulus of rupture,and a marked improvement in oxidation resistance.Compared with the sample without anhydrous borax,the sample with 4% anhydrous borax exhibits a decrease in apparent porosity by approximately 25%,an increase in cold modulus of rupture by about 5.6 times,and a reduction in the oxidized layer area by about 60%.

Effect of acidic environment on properties of silicon carbide castables

Liu Huiyong, Ding Yuhang, Cong Pei-yuan, Ma Xiaoyi, Xiang Bing, Xiong Jiquan, Zhang Zhong

2026, (1): 69-73. doi：10.3969/j.issn.1001-1935.2026.01.013

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To investigate the performance evolution of silicon carbide castables in acidic environments,silica sol-bonded silicon carbide castables were prepared using silicon carbide,α-Al₂O₃ micropowder,and silica sol as the main raw materials.The physical properties,microstructure,and phase composition of the castables after immersion in nitric acid of different concentrations (0,5%,10%,15%,and 20%,by mass) were studied.The results show that:(1)the surface of the dried specimens after acid immersion remains intact,without pulverization,peeling,or corrosion;(2)with the increase of the nitric acid concentration,the strength of the specimens improves,while the linear shrinkage and mass loss rate increase;(3)after immersion with 20% nitric acid,the phase composition does not change significantly,the bonding between surface particles becomes tighter,and the morphology becomes more even and orderly.It can be concluded that the silicon carbide castables have excellent acid corrosion resistance and can be used stably for a long time in various industrial acidic environments.

Effect of multi-fraction gradation of alumina ultrafines on medium and low temperature properties of corundum castables

Li Dongmei, Li Guimei, Yan Lin, Li Hongchao, Li Lu, Ye Qing, Shao Changbo, Chen Zhiqiang

2026, (1): 74-77. doi：10.3969/j.issn.1001-1935.2026.01.014

Abstract ( ) PDF (1303KB)( )

Corundum castables often exhibit a decline in strength during medium and low temperature stages of baking and field application,which adversely affects their overall performance.To solve this problem,an optimization of the particle gradation by using multi-graded alumina ultrafines was proposed to enhance the structural stability and mechanical properties of the castables after medium and low temperature heat treatment.With tabular corundum and six types of alumina ultrafines with varying particle sizes (d₅₀ of 3.910,1.885,1.362,1.104,0.798,and 0.524 μm,respectively) as the main raw materials,a five fraction gradation was designed.Its effects on the cold modulus of rupture (CMOR),permanent linear change on heating,and microstructure were systematically investigated.The results show that:(1)the samples with one-fraction or two-fraction gradation of ultrafines exhibit a significant decrease in cold modulus of rupture after heat treatment at 600 ℃ compared with those treated at 110 and 400 ℃;(2)the samples with a five-fraction gradation of ultrafines demonstrate stable performance in cold modulus of rupture within the 400-1 200 ℃ range,significantly mitigating the strength drop problem commonly encountered around 600 ℃ in traditional single-ultrafine systems.Meanwhile,the high-temperature-treated samples present a denser microstructure and more stable permanent linear change on heating.This study provides an effective strategy for optimizing the medium and low temperature performance of corundum castables,demonstrating a good engineering application value.

Effects of olivine additions on properties of magnesia-based coatings

Guo Yong, Zhu Yi, Yu Qiwen, Fu Xiao-yong, Xiao Xiong

2026, (1): 78-81. doi：10.3969/j.issn.1001-1935.2026.01.015

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To enhance the durability and reduce the cost of magnesia-based coatings for continuous casting tundishes,magnesia-based tundish coating materials were prepared using olivine,medium-grade magnesia clinker,and silica fume as the main raw materials,with magnesium sulfate heptahydrate as the binder.The effects of olivine additions (38%,45%,53%,61%,and 69%,by mass) on the phase composition,physical properties,and slag resistance of the coatings were researched.The results show that:(1)after heat treatment at 1 550 ℃,the main crystalline phases of the samples are periclase,forsterite,and stishovite.With the increasing olivine addition,the periclase content gradually decreases,while the forsterite and stishovite contents gradually increase;(2)at high temperatures,the magnesium ferrite and forsterite formed in the matrix exert a filling effect,leading to an increase in the bulk density and a decrease in the apparent porosity of the samples after heat treatment;(3)the expansive effect associated with the oxidation of FeO derived from the decomposition of fine olivine particles,coupled with the filling and strengthening effect of magnesium ferrite and forsterite on the matrix,results in unstable variation trends of the permanent linear change on heating and the cold compressive strength of the samples in different stages;(4)when the olivine addition is 61%,the coating exhibits the optimal slag resistance after being heat-treated at 1 550 ℃.

Research progress on reinforcement and toughening of silicon carbide-based composites

Wang Pengrui, Cheng Benjun, Liang Xiaocheng, Chen Fang, Wu Feng

2026, (1): 82-87. doi：10.3969/j.issn.1001-1935.2026.01.016

Abstract ( ) PDF (949KB)( )

The limitations of single-phase silicon carbide ceramics in fracture toughness and reliability restrict their applications in severer environments.This review summarized recent research progress on silicon carbide-based composites,including particle reinforcement,whisker reinforcement,and fiber reinforcement,focusing on the toughening mechanisms of different reinforcements,the corresponding preparation processes,and their influence on the final properties.The future development directions of silicon carbide-based composites were also prospected.

Research progress on cordierite-mullite saggers for ternary cathode firing of lithium-ion batteries

Zhu Zi-shuo, Wang Yilong, Su Yuming, Yang Liandi, Liu Qinghua, Qing Da, Wang Jian, Wu Feng, Han Lu

2026, (1): 88-92. doi：10.3969/j.issn.1001-1935.2026.01.017

Abstract ( ) PDF (934KB)( )

This article systematically reviewed the research progress on oxide saggars for high-temperature firing of ternary cathode materials of lithium-ion batteries,with a focus on the cordierite-mullite composite system.The formulation optimization design,corrosion resistance mechanisms,and the effects of surface modification techniques on material properties were discussed.By analyzing the impact of factors such as the ratio of aggregates to matrix,particle size distribution,types of binders,and the recycling of waste materials on the comprehensive performance of saggars,the intrinsic relationships among the material composition,structure,thermal shock resistance,and corrosion resistance were revealed.This study provides a systematic theoretical basis and technical pathway for the development of high-performance,long-life,and low-cost saggars,which is of great significance for ensuring the sintering quality of cathode materials and promoting the green and sustainable development of the lithiumion battery industry.