In this study, mullite– irconia composite samples were prepared by reaction sintering of alumina and zircon powder via gel casting process. Gel casting is a new ceramic forming technique. This process is based on the casting of slurry, containing ceramic powder, dispersant and premix monomer solution. To achieve stabilized, high solid loading (80 wt%) and castable slurry, the rheological properties of slurry were optimized. The monomers polymerized the slurry to form gelled specimens. After gelation, the specimens were unmolded, then dried out under controlled condition. Burning out and sintering of the specimens was carried out in the range of 1400-1700°C. Apparent porosity and bulk density of the sintered samples were measured by soaking in water. Crystalline phase evolution and microstructure were determined by XRD and SEM techniques. Results showed that the reaction sintering and mullite formation was completed at 1700°C due to very slow diffusion of Al3+ ions within amorphous silica formed at the decomposition of zircon. The sintered samples at this temperature also showed the lowest apparent porosity (≈ 4%) and the highest bulk density (≈3.40 gr/cm-3).

Keywords: Mullite- zirconia composite, Gel casting, Reaction sintering

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