A novel approach to synthesize SiC particles by in situ reaction in Al–Si–C alloys

•A novel approach to synthesize silicon carbide particles by in situ reaction in Al–Si–C melts was put forward.•The synthesis temperature for SiC particles can be as low as 750 °C•The size of in situ synthesized SiC particles increases from 0.2 μm to 10 μm as the reaction temperature increases.•The gradual-reaction mechanism was discussed.

In this article, a novel approach to synthesize SiC particles utilizing in situ liquid–solid reaction in Al–Si–C alloys was put forward. Unlike the traditional methods, the liquid–solid reaction method for in situ synthesis of SiC is direct, easy and can be used for mass production. The experimental results show that the synthesis temperature for SiC particles can be as low as 750 °C. The size of in situ synthesized SiC particles increases from 0.2 μm to 10 μm as the reaction temperature increases. Furthermore, it was found that SiC particles are in situ synthesized through gradual-reaction mechanism, and Al4C3 is the intermediate phase which is much easier to be synthesized in Al–Si–C system.