Preparation of lightweight corundum-mullite thermal insulation materials by microwave sintering

Lightweight corundum-mullite thermal insulation materials were successfully prepared by microwave sintering at low temperature. The effects of sintering temperatures, PMMA microspheres and SiC particles on structure and properties of as-prepared corundum-mullite materials were investigated. The SiC became a hot spot under the action of microwave field, and these local high temperature areas promoted the formation and growth of mullite whiskers. The PMMA microspheres were burn out, leaving pores which could provide space for the growth of mullite whiskers. It was found that the optimal sintering temperature was 1400?C and corresponding porosity, density and bending strength of the samples were 71.2%, 0.99 g/cm3 and 3.85MPa, respectively. The thermal conductivity was from 0.201 to 0.313W/(m?K) between 30?C and 950?C. This work demonstrated that lightweight corundum-mullite materials with low density, high porosity, good thermal shock resistance and excellent thermal insulation properties could be successfully prepared by microwave sintering.