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Guided by the corrosion mechanism in contact with Li(NixCoyMnz)O2 materials, a method was developed by wrapping refractory grains with a KAlSi2O6 (KAS4) layer for corrosion protection during the calcination of Li-ion battery (LIB) cathode materials. Preformed or in-situ KAS4 surrounds around refractory grains as a corrosion barrier by physically separating their contact with LIB materials. Because KAS4 did not react (or reacted little) with LIB materials, materials having in-situ or preformed KAS4 exhibit superior corrosion resistance, and in-situ KAS4 improves the corrosion resistance more. Additionally, the in-situ or preformed KAS4 also improves the thermomechanical properties of the prepared materials.

In this study, the degradation behavior of Al2O3-Ti3AlC2-Si-C refractories and a complete degradation process of Ti3AlC2 under a temperature gradient along the penetration direction were investigated by a dynamic corrosion at approximately 1630 °C. The degradation process of Ti3AlC2 affected the local liquid components by assisting to form CaAl12O19 and restrained CaO penetration via trapping into high-melting phase. On refractories-steel/slag interfaces affected by Marangoni convection, the molten steel penetration was suppressed in the samples with Ti3AlC2. A refined texture and increased viscosity, accompanying Ti3AlC2 oxidation and dissolution in molten steel, blocked the pathways and restrained the penetration of molten steel.

To assess the viability of an alumina-chromia refractory alternative for secondary copper smelters, the degradation behavior of alumina-chromia refractories in a secondary copper smelting slag and a Cu-CuxO mixture was studied via lab scale refractory finger testing. Microstructural characterization of the worn refractory samples resulted in a comprehensive understanding of the corrosion and penetration resistance and a comparison with the degradation of magnesia-chromite refractories. Alumina grains in the refractory are preferentially corroded by the slag. The alumina-chromia refractory exhibits superior infiltration resistance to the slag and the Cu-CuxO mixture compared to magnesia-chromite refractories.