Mullite (3AI2O3. 2Si02) is becoming increasingly important in electronic, optical, and high-temperature structural applications. This paper reviews the current state of mullite-related research at a fundamental level, within the framework of phase equilibria, crystal structure, synthesis, processing, and properties. Phase equilibria are discussed in terms of the problems associated with the nucleation kinetics of mullite and the large variations observed in the solid-solution range. The incongruent melting behavior of mullite is now widely accepted. Large variations in the solid solubility from 58 to 76 mot% alumina are related to the ordering/disordering of oxygen vacancies and are strongly coupled with the method of synthesis used to form mullite. Similarly, reaction sequences which lead to the formation of mullite upon heating depend on the spatial scale at which the components are mixed. Mixing at the atomic level is useful for lowtemperature (<lOOO"C) synthesis of mullite but not for low-temperature sintering. In contrast, precursors that are segregated are better suited for lowtemperature (1250" to 1500°C) densification through viscous deformation. Flexural strength and creep resistS M Wiederhorn-contributing editor

Mullite for Structural, Electronic, and Optical Applications

Porcelain represents the foundation of the ceramics discipline and one of the most complex ceramic materials. Composed primarily of clay, feldspar, and quartz, porcelains are heat-treated to form a mixture of glass and crystalline phases. This review focuses on raw materials, processing, heat treatment, and mechanical behavior. Because of the complexities of the porcelain system and despite the substantial amount of research already conducted within the field, there remain significant opportunities for research and study, particularly in the areas of raw material understanding, processing science, and phase and microstructure evolution.

Porcelain—Raw Materials, Processing, Phase Evolution, and Mechanical Behavior

Electrochemically-driven solid-state amorphization in lithium-silicon alloys and implications for lithium storage

All available thermodynamic and phase diagram data have been critically assessed for all phases in the CaO-Al2O3, Al2O3-SiO2, and CaO-Al2O3-SiO2 systems at 1 bar pressure from 298 K to above the liquidus temperatures. All reliable data for the binary systems have been simultaneously optimized to obtain, for each system, one set of model equations for the Gibbs energy of the liquid slag and all solid phases as functions of composition and temperature. The modified quasichemical model was used for the slag. With these binary parameters and those from the optimization of the CaO-SiO2 system reported previously, the quasichemical model was used to predict the thermodynamic properties of the ternary slag. Two additional small ternary parameters were required to reproduce the ternary phase diagram and ternary activity data to within experimental error limits. The calculated optimized phase diagram and thermodynamic properties are self-consistent and are the most reliable currently available estimates of the true values.

Critical evaluation and optimization of the thermodynamic properties and phase diagrams of the CaO-Al 2 O 3 , Al 2 O 3 -SiO 2 , and CaO-Al 2 O 3 -SiO 2 systems

Fiber-reinforced ceramic composites achieve high toughness through distributed damage mechanisms. These mechanisms are dependent on matrix cracks deflecting into fiber/matrix interfacial debonding cracks. Oxidation resistance of the fiber coatings often used to enable crack deflection is an important limitation for long-term use in many applications. Research on alternative, mostly oxide, coatings for oxide and non-oxide composites is reviewed. Processing issues, such as fiber coatings and fiber strength degradation, are discussed. Mechanics work related to design of crack deflecting coatings is also reviewed, and implications on the design of coatings and of composite systems using alternative coatings are discussed. Potential topics for further research are identified.

Interface Design for Oxidation‐Resistant Ceramic Composites

Concentration profiles of Al/sub 2/O/sub 3/ in diffusion couples made from sapphire and fused silica were used to determine the stable equilibrium phase diagram of the system SiO/sub 2/--Al/sub 2/O/sub 3/. The intermediate compound mullite, 3Al/sub 2/O/sub 3/.2SiO/sub 2/, melts incongruently at 1828 +- 10/sup 0/C; its stable solid-solution region ranges from 70.5 to 74.0 wt percent Al/sub 2/O/sub 3/ below 1753/sup 0/C and from 71.6 to 74.0 wt percent at 1813/sup 0/C. The microstructures of diffusion zones and heat-treated specimens also indicate the incongruency of mullite. Additional information is given for 3 metastable systems: SiO/sub 2/-Al/sub 2/O/sub 3/ in the absence of mullite, SiO/sub 2/-ordered-mullite in the absence of alumina, and SiO/sub 2/-disordered mullite in the absence of alumina. Under metastable conditions, ordered mullite melts congruently at approximately 1880/sup 0/C and its solid-solution range extends up to approximately 77 wt percent Al/sub 2/O/sub 3/. The solid-solution range of disordered mullite extends to approximately equal to 83 wt percent Al/sub 2/O/sub 3/ with an estimated congruent melting temperature of approximately 1900/sup 0/C. The existence of metastable systems is associated with superheating of mullite above the incongruent melting temperature and with nucleation of alumina and mullite in supercooled aluminum-silicate liquids. (auth)

I. A. Aksaf

Papers

Stable and Metastable Equilibria in the System SiO2-Al2O3