Research Progress in the Evaluation of Thermal Shock Resistance of Refractories: From Theoretical Evolution to Intelligent Characterization

The thermal shock resistance (TSR) of refractories is a critical determinant of the service life and operational safety of high-temperature industrial equipment in metallurgy, building materials, and chemical engineering. This paper systematically reviews the state-of-the-art research on the evaluation of TSR for refractories. On the theoretical level, the evolutionary logic from classical thermoelastic theory to energy-based damage theory, brittleness evaluation criteria, and the dimensional analysis-based RΠ theory is delineated, with a comparative analysis of the applicability of various criteria in dense versus porous material systems. Regarding evaluation methodologies, the strengths and limitations of conventional thermal cycling tests, splitting tests (notably Brazilian and wedge splitting), and specialized techniques such as ultrasonic pulsing and nano-indentation are scrutinized. Furthermore, the application of non-destructive monitoring technologies, such as Digital Image Correlation (DIC) and Acoustic Emission (AE), for in-situ damage capture is discussed. Additionally, the potential of machine learning in performance prediction and inverse material design is explored. Finally, it is posited that future research should focus on promoting the development of multiscale, standardized, and intelligent evaluation frameworks to meet the requirements of harsh operating environments in emerging fields such as green metallurgy.