Low Temperature Synthesis of Single-crystal Alpha Alumina Platelets by Calcining Bayerite and Potassium Sulfate

Single-crystal alpha alumina (α-Al2O3) platelets were synthesized by calcining a powder mixture of bayerite (α-Al(OH)3) and potassium sulfate (K2SO4) at 900℃. The crystalline phase evolutions and morphologies of the samples were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The synthesized samples mainly consisted of single-crystal α-Al2O3 platelets with a diameter of 0.5–1.5 μm and a thickness of 50–150 nm. Moreover, with 3, 5, and 8 wt% (referred to the obtained alumina) α-Al2O3 seeds adding into the powder mixture of bayerite and potassium sulfate, the average diameter of α-Al2O3 platelets can be reduced to 450, 240, and 220 nm, respectively. It is found that the sequence of the phase transformation is the bayerite (α-Al(OH)3) → boehmite (γ-AlOOH) → γ-Al2O3 → α-Al2O3. Further analysis indicated that K2SO4 can promote the phase transformation from γ-Al2O3 to α-Al2O3 and the formation of single-crystal α-Al2O3 platelets might be attributed to the liquid phase K3Al(SO4)3.