In situ mullite whisker network formation for high strength and lightweight ceramic proppants

Abstract

In this study, a facile in situ sintering method has been proposed for fabricating high strength lightweight mullite whisker network reinforced proppants. The effect of TiO2 on the microstructure, properties and fracture behaviours of the mullite whisker network was researched in detail. The addition of TiO2 promoted the formation of a modified mullite whisker network structure, which effectively improved the flexural strength. The sample containing 4 wt.% TiO2 exhibited an excellent flexural strength of 215.25MPa and low bulk density of 1.53 g/cm3 at 1400 ?C. The TiO2-added mullite whiskers mostly exhibited rod-like crystals with about 0.5- 0.8 ?m in diameter and 10-15 ?m in length. The as-prepared ceramic proppant showed excellent properties, such as low breakage ratio (2.19%under 52MPa), low density (1.36 g/cm3) and low acid solubility (2.28 wt.%).