Abstract
High-alumina fibre mats (Al 2O 3–4 wt.% SiO 2) were prepared with and without organic additives using a sol–gel spinning technique. The effect of processing variables during various stages of oxide fibre preparation, including sol spinning, drying and calcination, on the various types of defects generated were studied. The defects formed due to improper spinning can be diameter variations, hollow fibres, fibre sticking, and shots. The defects generated during calcination includes porous fibres, fibre cracking and core–sheath structures. As the organic content increased, surface roughness after calcination increased and the strength of the fibres decreased. Variations in heating schedules used in the calcination of alumina fibres also had a significant effect on properties of alumina fibre mats, either leading to the generation of fibre mats with good strength or dusty products. Fibres having strengths of 1.2 GPa and good handleability were obtained using a heating rate of 240 °C/h.
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