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Morphologically Textured Mullite in Sintered Tape-Cast Kaolin

Authors

  • Kai-Hsun Yang,

    1. Center for NanoScience and Department of Materials Science, National Sun Yat-Sen University,Kaohsiung 80424, Formosa
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  • Jia-Han Wu,

    1. Center for NanoScience and Department of Materials Science, National Sun Yat-Sen University,Kaohsiung 80424, Formosa
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  • Chi-Shiung Hsi,

    1. Department of Materials Engineering, National United University, Maioli 36003, Formosa
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  • Hong-Yang Lu

    Corresponding author
    1. Center for NanoScience and Department of Materials Science, National Sun Yat-Sen University,Kaohsiung 80424, Formosa
      †Author to whom correspondence should be addressed. e-mail: hyl@mail.nsysu.edu.tw
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  • A. Bandyopadhyay—contributing editor

  • This work was supported by the National Science Council of Taiwan through NSC-97-2221-E-110-012-MY3.

†Author to whom correspondence should be addressed. e-mail: hyl@mail.nsysu.edu.tw

Abstract

A commercial Malaysian kaolin powder made into an aqueous slurry was cast into green tapes ∼200 μm in thickness using the doctor-blade technique. A kaolinite (001)K(aolinite) texture was found on the green tapes using X-ray diffractometry (XRD). Subsequent sintering at 1600°C/1 h induces the preferred crystallographic orientations of (100)M(ullite), (110)M, (120)M, and (210)M in the mullite crystals thus formed by vitrification, as determined using electron backscatter diffraction. A nonunique orientation was observed on these crystals, suggesting that the texture is morphological with the c-axis, i.e., [001]M lying parallel to the sample surface, rather than crystallographical. An additional preferred orientation on (100)M, a forbidden reflection of the systematic absence from XRD is detected using pole figure. Kaolin is vitrified at 1600°C into mullite when the texture is developed, and sintering is initially facilitated by an SiO2–Al2O3 liquid formed at >1260°C, the eutectic temperature of metastable equilibrium. Further densification is promoted by additional particle rearrangement in an SiO2–mullite liquid formed at >1587°C, the stable equilibrium eutectic temperature. Alumina used as a substrate for the kaolin sintering does not play a significant role in developing the mullite morphological texture.

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