Ca–PSZ refractories were prepared from fused CaO–ZrO2 powder and characterised with respect to thermal expansion and phase composition. By modifying the stabilisation of ZrO2, the thermal expansion properties of the material were shown to have improved by the formation of a ‘plateau’ in the thermal expansion curve on cooling over the 500–800°C temperature range. Consequently, a Ca–PSZ refractory with better thermal shock resistance was obtained without adverse effect on the material density. Corrosion resistance should, therefore, also be maintained.
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