Abstract
Dissociation of zircon in a thermal plasma jet stream is utilized as a single-step process to prepare mullite/zirconia ceramic composites by plasma spraying zircon/alumina mixtures. The crystallization behavior of the zircon and alumina mixtures after plasma spraying was studied in the present paper. The spheroidized powders appear to have the characteristics of a single-phase mixture as well as that of diphasic mixture. Two exotherms were detected in the differential thermal analysis (DTA) curve up to 1600°C. The first exothermic peak in the DTA curve at 985°C is found to be due to the formation of primary mullite and spinel, while the second exotherm at 1250°C is due to secondary mullite formation. Cristobalite was found at a very narrow temperature range between 1050°C and 1100°C. The mullite that crystallized in the initial stage had a larger lattice parameter than the stoichiometric mullite.
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