Fabrication of Mullite-Alumina-SiC Composites by In-Situ Reaction during Carbothermal Reduction of Inorganic Materials

Mullite and alumina are common in high-temperature applications because of their low thermal expansion coefficient and good thermal shock resistance. Evolution of SiC in the matrix and using it as reinforcing phase can improve thermo-mechanical properties of these materials. Also, in-situ formation of the reinforcing phases by using inorganic materials is an economical process. In this work, crystallization of SiC as reinforcing phase in the matrix of mullite-alumina by carbothermal reaction processes of inorganic materials (andalusite and kaolinite) was studied. According to the ratio of C/SiO2 and process conditions, some properties of the composite such as phase transformation, microstructure and physical and mechanical properties were investigated. The results showed that optimal ratio of C/SiO2 and firing temperature of densification to form SiC crystals were 3.5 and 1600°C for andalusite and 5.5 and 1500°C for kaolinite.