Anisotropic Grain Growth and Microstructural Evolution of Dense Mullite above 1550°C

Abstract

Mullite powder with a nearly stoichiometric composition was hot‐pressed at 1550°C to produce an almost fully dense microstructure of fine, nearly uniaxial grains. The grain growth of the dense mullite was investigated during subsequent annealing at temperatures in the range of 1550–1750°C. Grain growth was relatively slow at 1550°C and the microstructure remained nearly equiaxial. Annealing at temperatures above the eutectic temperature (∼1590°C) produced fairly rapid anisotropic grain growth. At 1750°C, the anisotropic grain growth can be divided into two stages. In the first stage, the initial microstructure with an anisometric shape factor of 1.7 evolved rapidly into a microstructure with a shape factor of 2.7, consisting of a significant fraction of highly elongated grains. In the second stage, the microstructure evolved slowly into a system consisting of somewhat “blocky” grains with a shape factor of 2.2. The Al 2 O 3 content of the mullite grains increased slightly and reached an equilibrium value during the first stage of anisotropic grain growth. For the samples annealed at 1750°C, the indentation fracture toughness (2.5 ± 0.2 MPa · m 1/2 ) was almost independent of the anisometric shape factor. The interaction between the indentation cracks and the microstructure showed a predominantly transgranular mode of crack propagation. The data indicate that while a network of highly elongated grains can be developed by the present approach, some further manipulation of the grain boundary chemistry is required for an improvement of the fracture toughness.