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Abstract
Four different mullite-alumina-zirconia composites have been prepared by reaction sintering between alumina and zircon powders using magnesia or spinel (MgAi204) to increase the sintering and reaction rates. The microstructure of these materials can be described as composed of two parts: the first one is the mullite matrix containing various kinds of zirconia and alumina particles, whereas the second part is an amorphous phase in which alumina submatrices, zirconia and spinel particles are embedded. Examination of fracture surfaces allows one to identify the crack paths and shows that the main differences are related to zirconia inclusions. Analysis of mechanical properties and fracture features leads to the conclusion that crack deflection and microcracking are operative toughening mechanisms for the various materials. Moreover, a crack bowing mechanism is proposed to explain the higher modulus of rupture found for the series of materials prepared with magnesia as a reaction sintering aid.
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