Optimization of Ceramic Refractory Materials for Impact Pads in Tundish Systems for Continuous Steel Casting

Increasing demands on cast steel quality and the need to reduce carbon footprint drive the development of new refractory materials. A ceramic composition was developed for spherical tundish impact pads to ensure dimensional stability and resistance to erosion and corrosion. It consists of a thixotropic bauxite mixture with a sol-gel binder and 16% addition of tabular alumina, improving refractoriness and strength. The absence of cement-based binders allows fast, crack-free drying and higher fired strength. Compared to CAC-based castables, it reduces energy consumption and CO2 emissions. Plant trials confirmed excellent erosion resistance, with no surface deformation or steel penetration, demonstrating full functionality and durability of the pads under molten steel exposure. The material meets technical and environmental requirements, offering a viable alternative for sustainable steel casting operations.