Mullite whiskers reinforced SiC/Al2O3 composites were prepared by microwave
sintering in a microwave chamber with TE666 resonantmode. 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 30min. 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.
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