High-resolution TEM studies of mullite formation in metakaolinite
Studies on the compressive fracture strength (759 MPa at 15000°C) and the flexural strength (700MPaat 1300°C) of polycrystalline mullite (3Al2O3•2SiO2-2Al2O3•SiO2) illustrate its potential for high temperature applications. In the processing of these high strength mullites, molecularly mixed Al2O3-SiO2 precursors are used to enhance mullite formation rates and to achieve microstructural homogeneity in the submicrometer range. Reaction steps leading to the formation of mullite in molecularly mixed systems are not adequately understood. The prevailing problems center around (i) the composition of a spinel phase that forms at around a 980°C exothermic reaction, and (ii) the concurrent or subsequent formation and growth of mullite. Here, we report our high resolution TEM results on the formation of the spinel and mullite phases in a molecularly mixed precursor, metakaolinite (Al2O3•2SiO2).