Low temperature needle like mullite grain formation in sol–gel precursors coated on SiC porous substrates

Dense mullite coating having thickness in the range of 3 to 5 μm was produced from sol–gel mullite precursor coated on SiC porous substrates at heat treatment temperatures as low as 1300 °C. Mullite formed in the coating layer was characterised by X-ray diffraction. The precursors have an average particle size of 170 nm and the mullite formed in the coating in situ has a grain size of 3–5 μm. Mullite grains formed on the SiC have needle like morphology. The mullite formation has been explained on the basis of reaction between the silica–alumina nano precursor and the needle like morphology has been similar to that formed from a liquid phase. The gas permeation analysis shows that there is considerable difference between gas pressure while using SiC substrate before and after coating and hence clearly indicated reduction in pore size. This particular approach is good since usual mullite formation is at high temperature and is difficult to attain small grain size. Further, in situ formed mullite, in this investigation covers the SiC surface protecting the SiC from oxidation at high temperature.