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Upon application of nano-sized metallic Ni particles as catalyst, the in-situ synthesis mechanism of spinel whiskers in MgO–C refractories was studied. Their phase composition and morphology were determined by means of X-ray diffraction and scanning electron microscopy supported by energy dispersive spectroscopy. The results show that when the catalyst of nano-sized Ni was added in MgO–C refractories, the granular MgAl 2 O 4  (MA) spinels transformed into the shape of whiskers at 1 200 °C. The presence of Ni catalyst can accelerate the generation of Mg vapor, which can react with Al vapor to form MA spinel whiskers. Through dissolution and precipitation, MA spinel crystals nucleate directly and grow into whiskers from the catalytic droplets of nano-sized metallic Ni particles. The growth of spinel whiskers follows a typical vapor–liquid–solid (V–L–S) growth mechanism.

In-situ catalytic growth of MgAl 2 O 4 spinel whiskers in MgO–C refractories