Preparation of mullite whiskers reinforced SiC/Al2O3 composites by microwave sintering

Mullite whiskers reinforced SiC/Al2O3 composites were prepared by microwave sintering in a microwave chamber with TE666 resonant mode. Original SiC particles were coated with SiO2 using sol-gel processing and mixed with Al2O3 particles. Mullite was formed in the reaction between SiO2 and Al2O3. The isostatically pressed cylindrical pellets were sintered from 1350 °C to 1600 °C for 30 min. Physical and chemical responses were investigated by detecting changes in reflected power during the microwave sintering process. XRD was carried out to characterize the samples and showed that mullite could be formed at 1200 °C. Bridging of mullite whiskers between Al2O3 and SiC particles was observed by SEM and is due to a so-called local hot spot effect, which was the unique feature for microwave sintering. The optimized microwave sintering temperature was 1500 °C corresponding to the maximum amount of mullite whiskers within SiC/Al2O3 composites. The high electro-magnetic field enhanced the decomposition of mullite at higher temperatures above 1550 °C. The mechanical properties of mullite whiskers reinforced SiC/Al2O3 composites are much better than the SiC/Al2O3 composites without mullite whiskers