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Controlled densification of mullite for composite applications.

As part of an effort to fabricate oxide-based fibrous monolithic ceramics, sintering of mullite has been examined. The effects of Y{sub 2}O{sub 3} additions on sinterability of sol-gel-derived mullite and on the resulting microstructure were evaluated over a range of compositions, sintering times, and temperatures. Electron microscopy, X-ray diffraction, differential thermal analysis, and density measurements indicated that the Y{sub 2}O{sub 3} additions promoted densification through formation of a Y-Si-Al-O liquid phase. This phase tended to solidify as a glass during normal processing, but could be crystallized by a two-step annealing process at 1300 and 1200 C. The four-point flexural strengths of mullite and mullite-5 Wt.% Y{sub 2}O{sub 3} were also examined.