Effect of boehmite sol on the crystallization behavior and densification of mullite formed from a sol–gel precursor

Hybrid mullite sol was synthesized from an aqueous solution of aluminum nitrate (AN), aluminum isopropoxide (AIP) and tetraethylorthosilicate (TEOS), doped with boehmite sol with different ratios. Pressureless sintering of the xerogel was carried out at different temperatures in the presence of boehmite doping. The xerogel and sintered powder were characterized by FTIR, TG–DSC, XRD, SEM and bulk density. The addition of boehmite caused the formation of metaphase spinel (6Al2O3·SiO2) crystal before the appearance of mullite phase, which could lead to the formation of amorphous phase and suppress the premature formation of mullite. Both of these effects improve the densification of mullite. A maximum density about 98% of the theoretical density (TD, 3.01 g/cm3) of mullite could be obtained for 5 wt% boehmite addition at 1200 °C pressureless sintering.