A Novel Microstructural Evolution Model for Growth of Ultra-Fine Al2O3 Oxides from SiO2 Silica Ceramic Decomposition during Self-Propagated High-Temperature Synthesis

In this paper, experimental verification of the microstructural evolution model during sintering of aluminum, iron and particulate mullite ceramic powders using self-propagated high-temperature synthesis (SHS) was performed. The powder mixture with 20% wt. content of reinforcing ceramic was investigated throughout this research. The mixed powders were cold pressed and sintered in a vacuum at 1030 °C. The SHS reaction between sintered feed powders resulted in a rapid temperature increase from the heat generated. The temperature increase led to the melting of an aluminum-based metallic liquid. The metallic liquid infiltrated the porous SiO2 ceramics. Silicon atoms were transited into the intermetallic iron–aluminum matrix. Subsequently, a ternary matrix from the Fe–Al–Si system was formed, and synthesis of the oxygen and aluminum occurred. Synthesis of both these elements resulted in formation of new, fine Al2O3 precipitates in the volume of matrix. The proposed microstructural evolution model for growth of ultra-fine Al2O3 oxides from SiO2 silica ceramic decomposition during SHS was successfully verified through scanning electron microscopy (SEM), X-ray energy-dispersive spectroscopy (EDS) analysis and X-ray diffraction (XRD).