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Ca-α SiAlON powders were prepared at different starting compositions and carbon contents at 1450°C for 2 h in N2 from mixtures of SiO2, Al2O3, CaCO3 and carbon powders by carbothermal reduction–nitridation. Crystalline phases and particle morphology of the products were investigated. With increasing the x value in nominal Ca-α SiAlON compositions CaxSi12−3xAl3xOxN16−x, the number of small hollow spheres decreased and the size of primary grains consisting of the hollow spheres increased. The addition of carbon powder to more than 1.2 times of the necessary stoichiometric value was required to form Ca-α SiAlON hollow spheres composed of ultrafine grains.

Effects of starting composition and carbon content on the formation of Ca-.ALPHA. SiAlON powders by carbothermal reduction-nitridation