| IMS is a technique used to form fibers from low viscosity melts by means of stream stabilization in a reactant gas, in this case propane. Mullite (3Al{dollar}sb2{dollar}O{dollar}sb3cdot{dollar}2SiO{dollar}sb2{dollar}) was selected as the material to be fiberized. A stable mullite melt was obtained at 2000{dollar}spcirc{dollar}C. Some short fibers and shot were formed in the fiber forming experiments.; Crucible material selection is a prerequisite for proper application of the IMS technique. The effect of two crucible materials-graphite and boron nitride were studied. A carbothermal reaction occurred between the mullite melt and the graphite crucible. Boron nitride was selected as the crucible material because a relatively stable melt could be obtained. Operating environment is another factor that affects IMS mullite fiber formation. The effects of vacuum, nitrogen and argon on mullite melting behavior were studied. Argon gas was selected as the operating environment.; A 2{dollar}sp3{dollar} factorial design was developed to study the effect of such variables as temperature, holding time at the temperature, and heating rate on mullite melting behavior. The effects of the variables and interactions were calculated. Temperature has the biggest positive effect, holding time is the second, heating rate just has a very small negative effect.; A detailed investigation of the mullite decomposition mechanism and kinetics was conducted in this work. A solid reaction mechanism was proposed. The kinetic results and IR analysis support the proposed mechanism. The carbon source inside the furnace led to the decomposition of mullite. A feasible experimental technique was developed to prevent the decomposition of mullite. The experiments with this design completely controlled the mullite decomposition.; The short fibers, shot and some side products formed in the fiber forming experiments were characterized using XRD, XRF and SEM-EDS. The composition of the short fiber and shot was in the range of mullite composition. XRD showed that the diffraction pattern of shot is that of mullite. |
