Fabrication of one-dimensional rod-like α-SiAlON powders in large scales by combustion synthesis

α-SiAlON powders consisting of one-dimensional rod-like microcrystals were prepared by combustion synthesis in large scales. No obvious negative effect on reaction products was noticed by the increase of sample size, and α-SiAlON was synthesized as predominant phase in all the samples, even in CS-CL with the weight of 1000 g. These results showed good repeatability of combustion synthesis and its great potential in industrial production of α-SiAlON powders in large quantities. According to the phase composition of intermediate product, the reaction procedure in combustion synthesis of Ca α-SiAlON was proposed. At the same time, the strong influence of different starting compositions on the grain morphology of Yb α-SiAlON products was explained with the consideration of reaction temperature and grain growth character.