The effect of colemanite addition on the properties of mullite-zirconia composites prepared by slip casting

Abstract

Purpose: This study deals with the effects of colemanite (Ca2B6O115H2O) on properties ofslip-cast mullite–zirconia composites prepared via reaction–sintering of kaolinite, aluminaand zircon powders.Design/methodology/approach: Colloidal processing (slip casting) is the routetowards preparing these materials using 45 vol.% aqueous suspensions of a mixture offine powders stabilized with polyacrylate solution as a dispersant.Findings: The influence of powder composition on physical, mineralogical properties, andmicrostructure of these composites after firing at 1450, 1500 and 1550°C are observed.The results show that the density of composites tends to increase with the addition of7 wt.% colemanite. XRD analyses reveal that using colemanite during the synthesis ofmullite-zirconia composites lowers the reaction temperature. All of the composites consistof irregularly shaped mullite and round-shaped zirconia grains, which are distributedhomogenously.Practical implications: Mullite–zirconia composites, owing to their chemical inertnessand good resistance against chemical attack-corrosion by siliceous and metallic melts, theyare employed in the glass industry.Originality/value: Reaction sintering process is considered as a promising technology forpreparing mullite-zirconia composites, because it has some advantages such as low costof traditional raw materials, straightforward production technology and low manufacturingcost.