Synthesis and Characterazation of the Mullite-Zirconia Composite Material

Mullite-Zirconia (3Al3O2.2SiO2.ZrO2) composite, was an important industrial material, which has been synthesized by a solid state reaction method from its constituent (3Al2O3.2SiO2) and zirconia (ZrO2). Mullite has been synthesized by sol-gel method from raw materials, pure aluminum (98-100%), pure silica foam (99.9-100%), and aluminum chloride hexahydrate (AlCl3.6H2O) and calcined at 1200°C for 2 hr. Mullite has been a matrix and the reinforced component addition were 5 %, 10 %, and 15% of zirconia.The phase and microstructure evolutions of the composite synthesized at desired temperature of 1150, 1350, and 1450°C were characterized by x-ray diffractometry and scanning electronic microscopy, respectively. The influences of sintering temperature on shrinkage ratio, apparent porosity and bulk density. The formation process of the composites were examined. The results showed that the zirconia-mullite composites or zirconia reinforced mullite (ZRM) with good sintering properties could be prepared at 1450°C for 2 hr.

Keywords:

Mullite , Zirconia , Sol-Gel , Solid-State , and Zirconia reinforced Mullite (ZRM)