Formation mechanism of β-Sialon with different morphologies based on DFT calculation and its effect on the performance of refractory composites

β-Sialon with whisker-like, columnar, and plate-shaped structures was successfully synthesized with Al2O3–C refractory compositions. In the presence of a catalyst, the preferential growth face of columnar β-Sialon was (100), whereas plate-like β-Sialon preferred (101) and (111). DFT calculations demonstrated that the SiO adsorption energy on the (100), (101), and (111) faces of β-Sialon crystal were –34.95, –52.88, and –45.08 eV, respectively. Therefore, the (101) and (111) faces were more stable in Al-rich β-Sialon. With the increase in catalyst content, the Si-rich Si–Al–O–N liquid phases, which contributed to the generation of columnar β-Sialon, were converted into the Al-rich Al–Si–O–N system that was conducive to the formation of plate-like β-Sialon. Compared to the sample without the catalyst, the CMOR and HMOR of the specimen were increased by 45.07% and 60.47%, respectively, with the addition of Fe2O3. This was attributed to the formation of β-Sialon with a one- or two- dimensional shape.