STRUCTURAL
CERAMIC MATERIALS
MULLITE – Structure, Properties, Applications
Mullite – 3Al2O3.2SiO2
Mullite was first described in 1924 for an occurrence on the Isle of Mull, Scotland. It occurs
as argillaceous inclusions in volcanic rocks in the Isle of Mull, inclusions in sillimanite.
Mullite is present in the form of needles in porcelain. It can form two stoichiometric forms:
3Al2O3 2SiO2 or 2Al2O3 SiO2. Unusually, mullite has no charge balancing cations present.
As a result, there are three different aluminium sites: two distorted tetrahedral and one
octahedral.
Mullite – 3Al2O3.2SiO2
Mullite has achieved outstanding importance as a material for both traditional and advanced
ceramics because of its favourable thermal and mechanical properties.
The crystal structure of mullite is closely related to that of sillimanite, which is characterized
by chains of edge-connected AlO6 octahedra running parallel to the crystallographic c-axis.
Mullite has orthorhombic crystal system.
Mullite – 3Al2O3.2SiO2 Types
Natural Mullie
Synthetic Mullite
• Sintered Mullite
• Fused Mullite
ZirMul (Zirconia Mullite)
Mullite – 3Al2O3.2SiO2 Properties
• Good electrical resistivity
• Optimal high-temperature strength
• Superior thermal stability
• Good thermal shock resistance
• Resistance to abrasion
• Resistance to oxidation and attack, in furnace atmospheres
• Resistance to a range of chemical attacks; it exhibits outstanding stability in acid metal
slags, and is insoluble in a majority of the acids.
• The approximate limiting temperature of use is 1600 °C in a vacuum and 1800 °C in air
Mullite – 3Al2O3.2SiO2 Properties
Property
Density (g/cm3) 3.03
Young’s Modulus (GPa) 130
Fracture Toughness (MPa.m-1/2) 2-4
Modulus of Rupture (MPa) 160
Thermal Expansion Co-Efficient (x10-6 /°C) 4.5-5.6
Thermal Conductivity (W/m.K) 4.0-6.0 (100-1400 °C)
Maximum Operating Temperature (°C) 1725 °C in air
Mullite – 3Al2O3.2SiO2 Applications
Refractories
Overall, the largest application of mullite-based products is in refractories. The steel and
glass industries are two key markets.
The steel sector is the largest user, where refractoriness, thermal shock resistance, and high
creep resistance are crucial. High-mullite-based products are primarily used in hot blast
stove checker bricks.
A number of refractories in the steel sector have different amounts of mullite-based
aggregates. Reheat furnaces, steel ladles, slide gates, and lances are examples of mullite-
aggregate-based products with different levels of alumina content. The decrease in the use
of bricks has led to an increase in the use of monolithic and precast shapes.
Mullite – 3Al2O3.2SiO2 Applications
Refractories
In the glass industry, mullite-based refractories are used in ports, burner blocks, and in
checker bricks. These refractories are also used in the drawing chambers as well as in the
upper structure of the tanks, where glass is melted. Thermal shock resistance, high hot
strength, chemical attack resistance, and creep resistance are the key properties valued by
the industry.
Mullite-based products also have resistance to particulate carryover into the glass melt. This
is especially crucial in the production of flat glass, where contamination by low levels of
Al2O3 is detrimental.
The ceramic industry is the next major user of mullite, especially in kiln furniture items like
kiln setter slabs and posts that support ceramic-ware during firing.
Mullite – 3Al2O3.2SiO2 Applications
In addition, the petrochemical and aluminum industries use mullite-based aggregates for
applications that necessitate thermal shock resistance, chemical attack resistance, and hot-
load strength.
Other Engineering Applications
New mullite materials with optimally controlled physical and mechanical properties have
enabled the extensive use of the material.
Due to the optimal mechanical properties of high-purity mullites at high temperatures, they
have been potentially used in high-temperature engineering ceramics, for instance, in
turbine engine parts.
Mullite is also a desirable material for high-strength infrared transmitting windows.
Protective coatings and electronic substrates are other applications of mullites.
