Effects of precursor pH and sintering temperature on synthesizing and morphology of sol–gel processed mullite

Needlelike mullite, which shows high aspect ratios, has been synthesized by coprecipitation from aluminum nitrate enneahydrate and colloidal silica sols. The effects of precursor pH and sintering temperature on the synthesizing behavior and the morphology of the needlelike mullite have been investigated. The equilibrium mullite phase appeared in the samples, which had been sintered at and above 1200 °C for each precursor pH. Crystallization of cristobalite from excessive SiO2 occurred during sintering from 1200 °C, and the amount of cristobalite increased with sintering temperature up to 1400 °C. However, resorption of cristobalite into mullite decreased the amount of the phase from 1500 °C. The mullite synthesized with precursor pH⩽2 (acidic sample) displayed high aspect ratios at high sintering temperature. However, morphology of the mullite synthesized with precursor pH⩾8 (basic sample) transformed to rodlike or granular shape with increasing sintering temperature.