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Synthesis of highly dispersed α-Al2O3 platelets in KCl–K2SO4–Na2SO4 composite flux

Abstract Alpha-alumina platelets have attracted much attention in recent years, due to their high fracture toughness, high elastic modulus, high strength and good corrosion resistance. In this paper, α-Al2O3 platelets were successfully synthesised by flux method using γ-AlOOH powder as starting material, KCl–K2SO4–Na2SO4 composite salts as flux respectively. Differential scanning calorimetry (DSC) and thermogravimetric (TG) analysis showed that the flux has a low melting point of about 560±1°C and well stability even under temperature of 900°C, which is beneficial for the steady reaction and crystal growth under low temperature. Highly dispersed and hexagonal single crystal α-Al2O3 platelets can be well formed at temperature of 900°C, and the average size of the platelets is about 6–7 μm.