Abstract
Ca-α-SiAlON ceramics with high porosity and fine rod-like grains were fabricated using unidirectional freezing and pressureless sintering. The high porosity of green body was maintained during sintering, which was mainly controlled by solid loading of slurry. Phase analysis showed that α-SiAlON was major phase while small amount of AlN’ was inevitable. The anisotropic growth of α-SiAlON was controlled by sintering temperature, fine rod-like α-SiAlON grain morphology was obtained after sample was sintered at 1810℃ for 1.5 h. The aligned channel became more uniform with higher solid loading, gave rise to better mechanical properties. The fabricated samples demonstrated remarkably comprehensive properties including low thermal conductivities, low dielectric constant and dielectric loss.
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