Hostname: page-component-78c5997874-94fs2 Total loading time: 0 Render date: 2024-11-15T07:28:15.523Z Has data issue: false hasContentIssue false
  • English
  • Français

Influence of excess alumina on mullite synthesized from pyrophyllite by spark plasma sintering

Published online by Cambridge University Press:  28 July 2020

Rasidi Sule Open the ORCID record for Rasidi Sule [Opens in a new window]  and
Iakovos Sigalas
Rasidi Sule*
Affiliation:
Nanotechnology and Water Sustainability Research Unit, College of Science, Engineering & Technology, University of South Africa, Florida Science Campus, Johannesburg, South Africa
Iakovos Sigalas
Affiliation:
DST-NRF Centre of Excellence in Strong Materials, University of Witwatersrand, Johannesburg, South Africa School of Chemical and Metallurgical Engineering, University of the Witwatersrand, Johannesburg, South Africa
*
*E-mail: [email protected]
Get access Rights & Permissions [Opens in a new window]

Abstract

The influence of excess Al2O3 on 3:2 mullite produced from α-Al2O3 and pyrophyllite powder was examined. A mixture consisting of 28 wt.% dehydroxylated pyrophyllite and 72 wt.% α-Al2O3 was milled in an attrition mill. The milled powders were sintered by spark plasma sintering (SPS) at 1600°C for 10, 20 and 30 min. Subsequently, the samples were heated at 1350°C for 2 h to determine the influence of the excess Al2O3 on the microstructure. No glassy phase was detected in the sample containing 72 wt.% Al2O3 and sintered at 1600°C for 20 min. The sample with 72 wt.% Al2O3 had greater hardness and fracture toughness compared to 3:2 mullite. The greatest hardness and fracture toughness of 12.43 GPa and 2.71 MPa m–0.5, respectively, were obtained in the sample containing 72 wt.% Al2O3 sintered at 1600°C for 20 min.

Keywords

mechanical propertiesmicrostructurepyrophyllitesynthesis
Type
Review Article
Information
Clay Minerals , Volume 55 , Issue 2 , June 2020 , pp. 166 - 171
Copyright
Copyright © The Mineralogical Society of Great Britain and Ireland, 2020

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

Footnotes

Associate Editor: Huaming Yang

References

Aguilar-Santillan, J., Balmori-Ramirez, H. & Bradt, R.C. (2007) Dense mullite from attrition milled kyanite and alpha-alumina. Journal of Ceramic Processing Research, 8, 1–11.Google Scholar
Aksay, I.A., Dabbs, D.M. & Sarikaya, M. (1991) Mullite for structural, electronic, and optical applications. Journal of the American Ceramic Society, 74, 2343–2358.CrossRefGoogle Scholar
Aksel, C. (2003) The effect of mullite on the mechanical properties and thermal shock behaviour of alumina–mullite refractory materials. Ceramics International, 29, 183–188.CrossRefGoogle Scholar
Anstis, G., Chantikul, P., Lawn, B.R. & Marshall, D. (1981) A critical evaluation of indentation techniques for measuring fracture toughness: I, direct crack measurements. Journal of the American Ceramic Society, 64, 533–538.CrossRefGoogle Scholar
Cascales, A., Tabares, N., Bartolomé, J.F., Cerpa, A., Smirnov, A., Moreno, R. & Nieto, M.I. (2015) Processing and mechanical properties of mullite and mullite–alumina composites reinforced with carbon nanofibers. Journal of the European Ceramic Society, 35, 3613–3621.CrossRefGoogle Scholar
Chen, C., Lan, G. & Tuan, W. (2000) Preparation of mullite by the reaction sintering of kaolinite and alumina. Journal of the European Ceramic Society, 20, 2519–2525.CrossRefGoogle Scholar
Gao, L., Jin, X., Kawaoka, H., Sekino, T. & Niihara, K. (2002) Microstructure and mechanical properties of SiC–mullite nanocomposite prepared by spark plasma sintering. Materials Science and Engineering: A, 334, 262–266.CrossRefGoogle Scholar
Ghahremani, D., Ebadzadeh, T. & Maghsodipour, A. (2015) Spark plasma sintering of mullite: relation between microstructure, properties and spark plasma sintering (SPS) parameters. Ceramics International, 41, 6409–6416.CrossRefGoogle Scholar
Khor, K.A., Yu, L., Li, Y., Dong, Z.L. & Munir, Z. (2003) Spark plasma reaction sintering of ZrO2–mullite composites from plasma spheroidized zircon/alumina powders. Materials Science and Engineering: A, 339, 286–296.CrossRefGoogle Scholar
Kim, W., Chae, W., Kwon, S., Kim, K., Lee, H. & Kim, S. (2014) Effect of dry grinding of pyrophyllite on the hydrothermal synthesis of zeolite Na-X and Na-A. Materials Transactions, 99, 1488–1493.CrossRefGoogle Scholar
Kool, A., Thakur, P., Bagch, B., Hoque, N.A. & Das, S. (2015) Mechanical, dielectric and photoluminescence properties of alumina–mullite composite derived from natural Ganges clay. Applied Clay Science, 114, 349–358.CrossRefGoogle Scholar
Medvedovski, E. (2006) Alumina–mullite ceramics for structural applications. Ceramics International, 32, 369–375.CrossRefGoogle Scholar
Mukhopadhyay, T.K., Dana, K. & Ghatak, S. (2011). Pyrophyllite-a potential material for application in tri-axial porcelain systems. Industrial Ceramics, 31, 165–173.Google Scholar
Mukhopadhyay, T.K., Ghatak, S. & MaitI, H.S. (2010) Pyrophyllite as raw material for ceramic applications in the perspective of its pyro-chemical properties. Ceramics International, 36, 909–916.CrossRefGoogle Scholar
Olszyna, A., Marchlewski, P. & Kurzydłowski, K. (1997) Sintering of high-density, high-purity alumina ceramics. Ceramics International, 23, 323–328.CrossRefGoogle Scholar
Sadik, C., Amrani, I.-E.E. & Albizane, A. (2014) Processing and characterization of alumina–mullite ceramics. Journal of Asian Ceramic Societies, 2, 310–316.CrossRefGoogle Scholar
Saeidabadi, E.K., Ebadzadeh, T. & Salahi, E. (2018) Preparation of mullite from alumina/aluminum nitrate and kaolin clay through spark plasma sintering process. Ceramics International, 44, 21053–21066.CrossRefGoogle Scholar
Schneider, H,, Fischer, R.X. & Schreuer, J. (2015) Mullite: crystal structure and related properties. Journal of the American Ceramic Society, 98, 2948–2967.CrossRefGoogle Scholar
Suárez, M., Fernández, A., Menéndez, J., Torrecillas, R., Kessel, H., Hennicke, J. et al. (2013) Challenges and opportunities for spark plasma sintering: a key technology for a new generation of materials. Sintering Applications, 13, 319–342.Google Scholar
Sule, R. & Sigalas, I. (2018) Effect of temperature on mullite synthesis from attrition-milled pyrophyllite and α-alumina by spark plasma sintering. Applied Clay Science, 162, 288–296.CrossRefGoogle Scholar
Taylor, H. (1962) Homogeneous and inhomogeneous mechanisms in the dehydroxylation of minerals. Clay Minerals Bulletin, 5, 45–55.CrossRefGoogle Scholar
Tripathi, H.S., Das, S., Mukherjee, B., Ghosh, A. & Banerjee, G. (2001) Synthesis and thermo-mechanical properties of mullite–alumina composite derived from sillimanite beach sand: effect of ZrO2. Ceramics International, 27, 833–837.CrossRefGoogle Scholar
Yahya, H., Othman, M.R. & Ahmad, Z.A. (2016) Effect of mullite formation on properties of aluminosilicate ceramic balls. Procedia Chemistry, 19, 922–928.CrossRefGoogle Scholar
Yamuna, A., Devanarayanan, S. & Lalithambika, M. (2002) Phase-pure mullite from kaolinite. Journal of the American Ceramic Society, 85, 1409–1413.CrossRefGoogle Scholar
Yan, W., Li, N. & Han, B. (2010) Effects of sintering temperature on pore characterisation and strength of porous corundum–mullite ceramics. Journal of Ceramic Processing Research, 11, 388–391.Google Scholar
Zhang, G., Wang, Y., Fu, Z., Wang, H., Wang, W., Zhang, J. et al. (2009) Transparent mullite ceramic from single-phase gel by spark plasma sintering. Journal of the European Ceramic Society, 29, 2705–2711.CrossRefGoogle Scholar