Porous mullite ceramics through diphasic gels of large boehmite and small silica particles

Mullite formation process has been studied in stoichiometric mullite (3Al₂O₃·2SiO₂) diphasic gel containing large boehmite (1 m) and small silica (10 nm) particles. It has been found that initial mullitization did not take place inside the silica phase (cristobalite), but took place in the defect -alumina phase. -alumina was stabilized by silica when the temperature was below 1350°C. At temperatures above 1350°C, mullite crystallized directly. It was suggested that silica diffused into the pores (<1.8 nm) of -alumina and prevented the collapse of -alumina pore structure. On the other hand, when silica was not present, the pore structure of -alumina collapsed and -alumina crystallized at 1100°C. Porous mullite ceramics were obtained by using special diphasic gels containing large boehmite and small silica particles.