Abstract
Reaction sintering of zircon and alumina is an easy and inexpensive route to obtain homogeneous mullite-zirconia ceramics with enhanced mechanical properties. This paper presents the preparation of ZrO 2 reinforced mullite by plasma spraying a mixtures of zircon and alumina. The results indicate that the plasma sprayed powders consist of zirconia, zircon and alumina. It was found that fine grained, even amorphous and chemically homogeneous composite powders can be obtained by ball milling and plasma spraying. Recrystallization of amorphous phases and the formation of mullite occurred at ∼1000°C in plasma sprayed powders. This value is more than 500°C lower than the formation of mullite in as-milled powders. The effect of power and secondary gas pressure on the spheroidization of zircon and alumina mixtures was investigated. The results showed that both of them were of importance in controlling the morphology and phase composition of the spheroidized powders.
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