Preparation of Mg-α SiAlON powder by carbothermal reduction-nitridation of talc and halloysite

Carbothermal reduction-nitridation (CRN) of talc (Mg3(Si2O5)2(OH)2) and halloysite (Al2Si2O5(OH)4) clay provides a useful route for preparing low-cost Mg-α sialon powder. In this study, the chosen molecular ratios of talc to halloysite were 0.1:1, 0.2:1, 1.5:1.0 and 2.0:1. The CRN reaction was conducted at 1450 to 1520 deg C and 2 to 6h holding time using carbon black as a reducing agent in flowing N2 (gas). The results showed the synthesized powder was composed of α-sialon, β-sialon and small amounts of SiC, 15R and AlN phases that greatly depended on the ratio of talc to halloysite, the reaction temperature and holding time. The highest content of Mg-α sialon, as much as 90wt%, was achieved at 1480 deg C for a holding time of 4h at a talc to halloysite ratio of 1.5:1.0. SiC was considered as an intermediate compound. We also discuss the evaporation loss of Mg caused by talc decomposing into MgSiN2 intermediate phase in the CRN reaction. Copyright (2001) The Australian Ceramic Society