Synthesis and characterization of sol-gel derived monophasic mullite powder

Abstract High-purity microfine mullite precursor powder of stoichiometric chemical composition, 3Al2O3.2SiO2, was synthesized through the sol-gel route using aluminum isopropoxide and tetraethyl orthosilicate. The derived mullite precursor powder was characterized by BET surface area, particle size distribution, Fourier-transform infrared spectroscopy, thermogravimetry-differential thermal analysis (TG-DTA), X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy. Phase analysis of the precursor powder and calcined samples at different temperatures was done by XRD. Non-isothermal crystallization kinetics of mullite precursor was studied by TG-DTA in static air using heating rates of 5.0, 7.5, 10.0, 12.5, and 15 K.min-1. Grain morphology was studied by SEM. The results showed that synthesized mullite precursor powder possessed homogeneity of Al and Si components, and the amorphous precursor powder was converted to monophasic mullite crystal when heat-treated at 970 °C. Based on Flynn-Wall-Ozawa and Kissinger equations, the activation energy associated with the crystallization of mullite was determined to be 1189.8 and 1189.0 kJ.mol-1, respectively.