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Why do coarse grains help some refractories resist cracking?
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In the context of industrial materials, coarse grains are incorporated into the microstructure of refractories to improve their resistance to thermal shock.
When a refractory material is rapidly cooled, the surface layers contract against the inner layers, creating tensile stress that can cause cracks to propagate. While a coarse microstructure—often featuring filler grains on the scale of millimeters—may reduce the overall load-bearing strength of the material, these large grains serve a critical function: they act to blunt the tips of developing cracks. By arresting the progression of these cracks, the coarse grains help the material withstand the stresses of rapid temperature changes.1