Abstract

An attempt has been made to prepare stoichiometric mullite powders by mixing aluminium nitrate and TEOS in different solvents like distilled water, ethanol and methanol. The sol obtained was spray dried and the powders were calcined in the range 850°-1000°C and sintered at 1600°C. XRD patterns of these powders calcined at 1000°C showed mullite formation in all the solvent systems. Thermal analysis data indicated mullite exotherm below 1000°C. A 10% increase in density was observed on sintering at 1600°C preferentially for methanol derived powder. Fractographs of the sintered mullite generally showed localised densification indicating the inhomo-geneity in the precursor. A controlled hydrolysis of the precursor under different solvent media was indicated to influence the gelation characteristics and bring down the extent of inhomogeneity. A correlation has been presented with respect to history of gelation and the formation of a mullite phase as well as development of sintered microstructure.

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