Abstract:Highly pure Al 4 SiC 4 powders were prepared by carbothermic reduction at 2173 K using Al 2 O 3 , SiO 2 , and graphite as raw materials. The obtained Al 4 SiC 4 powders owned hexagonal plate-like grains with a diameter of about 200-300 μm and a thickness of about 2-6 μm. Based on the experimental results, the reaction of Al 4 SiC 4 formation and grain evolution mechanisms were determined from thermodynamic and first-principles calculations. The results indicated that the synthesis of Al 4 SiC 4 by the carbothermic reduction consisted of two parts, i.e., solid-solid reactions initially followed by complex gas-solid and gas-gas reactions. The grain growth mechanism of Al 4 SiC 4 featured a two-dimensional nucleation and growth mechanism. The gas phases formed during the sintering process favored the preferential grain growth of (0010) and (1 10) planes resulting in formation of hexagonal plate-like Al 4 SiC 4 grains.