Synthesis and thermo-mechanical properties of mullite–alumina composite derived from sillimanite beach sand: effect of ZrO2

A mullite–alumina composite was developed by reaction sintering of sillimanite beach sand and calcined alumina. ZrO2 (2–6 wt.%) was added as additive. The raw materials and additive were mixed, attrition milled and sintered in compacted form at 1400–1600°C with 2 h soaking. The effect of ZrO2 on the densification behaviour, thermo-mechanical properties and microstructure was studied. It was found that addition of ZrO2 slightly retards the densification process. All the samples achieved their highest bulk density at 1600°C. Thermo-mechanical properties of the sintered samples are not effectively altered by the presence of ZrO2. ZrO2 containing samples always show better resistance to thermal shock than the ZrO2 free samples. Scanning electron micrography shows that ZrO2 occupies both an intergranular and intragranular position in the mullite matrix. The mullite formed at 1600°C is mostly equiaxed in nature that suggests densification mainly occurs through solid state sintering.