Control of calcium hexaluminate grain morphology in in-situ toughened ceramic composites

The influence of processing conditions on the morphology of calcium hexaluminate (CA₆) grains in Al₂O₃: 30 vol% CaO·6Al₂O₃ (CA₆) ceramic composites was investigated. Specimens were prepared by in-situ reaction sintering using precursor powders of alumina, and either calcium carbonate or calcium oxide. In some samples, 1 vol% anorthite glass was added as a sintering aid. X-ray diffraction was used to study the phase development in the as-calcined and sintered states. The resultant microstructures were characterized using both scanning electron microscopy (SEM), and imaging secondary ion mass spectrometry (SIMS). It was found that the CA₆ grains developed a platelike morphology when CaCO₃ was used as the starting calcium-rich powder. In contrast, samples prepared using CaO resulted in equiaxed CA₆ grains. This result was observed to be independent of the anorthite glass addition. The findings are rationalized in terms of distinct CA₆ reaction mechanisms, resulting from differences in the reactivity of the powders during the early stages of calcining.Cement Nomenclature C CaO - A Al₂O₃