Thermal decomposition and reaction sintering for synthesis of mullite-zirconia composite using kaolin, γ-alumina and zirconia

• Autor(a) principal: Aswad,M. A.
• Data de Publicação: 2021
• Outros Autores: Alfatlawi,S. H. A., Saud,A. N.
• Tipo de documento: Artigo
• Idioma: eng
• Título da fonte: Cerâmica (São Paulo. Online)
• Texto Completo: http://old.scielo.br/scielo.php?script=sci_arttext&pid=S0366-69132021000100032
• topic: Iraqi kaolin; gamma-alumina; zirconia; mullite; composite materials; thermal decomposition process; reaction sintering

Abstract The refractory materials used in the wall of the furnaces for glass melting can be prepared from mullite-zirconia composite material. The composite of mullite/zirconia was synthesized from Iraqi kaolin, γ-alumina, and zirconia using thermal decomposition with reaction sintering at 1600 °C. Several batches were prepared with various ratios of kaolin, γ-alumina, and zirconia, and the composite compositions were selected from the Al2O3-SiO2-ZrO2 phase diagram. The mullite-zirconia composite was prepared with different steps beginning with milling the starting materials, semi-dry uniaxial pressing, and then reactive sintering at various temperatures (1200, 1400, and 1600 °C). The predicted phases ZrO2 and Al6Si2O13 were identified by X-ray diffraction patterns according to the phase diagram for all the batches. The lower amount of the zirconia added to mullite reduced porosity and improved the bulk density of the mullite/zirconia composite. The thermal expansion coefficient slightly increased with the addition of zirconia. It also enhanced the thermal shock resistance of the composite. Finally, the mechanical properties were improved by increasing the amount of zirconia particles in a matrix of mullite due to the phase transformation of zirconia from tetragonal to monoclinic phase.