Mechanical properties of reinforced porcelain slabs with mullite whiskers introduced by aluminum silicate fiber

Mullite whiskers (3Al 2 O 3 ·2SiO 2 ) reinforced porcelain slabs with high bending strength and fracture toughness were successfully prepared by calcining a kaolin-potash feldspar-albite mixture with aluminum silicate fibers (ASF, Al 2 O 3 ·SiO 2 ). Effects of ASF content on the properties of porcelain slabs were investigated. Bending strength and fracture toughness of the samples reach the peak values, 39% and 19% higher than that of the blank samples when the amount of ASF is 5 wt%. The elongated and needle-like mullite whiskers are obtained in the substrates with ASF fiber addition, differing from the rod-shaped mullite whiskers in the blank ones. During the sintering process, ASF provides growth environment and ingredient for elongated mullite whiskers. The in-situ generated elongated mullite whiskers link the porcelain slabs substrate as a bridge and consume more energy before the fracture occurred. Therefore, mullite whiskers induced by ASF can offer reliable opportunity for preparation of porcelain slabs with good mechanical properties.