Abstract

In this study, we developed a novel method for synthesising Al2OC-AlNss using a solid nitrogen source: a Si3N4 mesophase. The two-step sintered Al–Al2O3 and Si3N4–Al–Al2O3 samples were prepared under an atmosphere of nitrogen to investigate the effect of Si3N4 on the formation of Al2OC-AlNss in resin-bonded Al–Al2O3 composites. The samples were investigated via XRD and SEM. The results indicated that the synthesis of Al2OC-AlNss with different morphologies was achieved via the Si3N4 mesophase, and its morphology was influenced by the source of AlN. Both Al2OC-AlNss and Al4O4C were formed in the two-step sintered Al–Al2O3 sample, whereas only Al2OC-AlNss was formed in the two-step sintered Si3N4–Al–Al2O3 sample. Induced by the AlN formed by the nitridation of Al, needle-like Al2OC-AlNss was generated. Compared to that formed by the nitridation of Al, more AlN nuclei were provided by the reaction between Si3N4 and Al. Subsequently, columnar and granular Al2OC-AlNss were formed. Furthermore, fibre-like Al2OC-AlNss was also generated via the VS and VLS mechanism. The reaction model was established in this study.

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