Sialons from Natural Aluminosilicates

The synthesis of the high-temperature material sialon (Si{sub 6{minus}z}Al{sub z}O{sub z}N{sub 8{minus}z}) by carbothermic reduction followed by nitridation has been examined. Kaolin, sillimanite, and pyrophillite can be converted to {beta}{prime}-sialon having z values of 2, 2.5, and 0.8, respectively. Other phases that appear in small quantities along with the sialon are mainly alumina and mullite, and trace amounts of AlN and the AlON spinel phase also form. The carbon content at {ge}90% theoretical is very sensitive to nitrogen uptake and phase composition. The uniform mixing of carbon with clay is equally important. Fireclay without an Fe{sub 2}O{sub 3} catalyst produces the same product that does kaolin with an Fe{sub 2}O{sub 3} catalyst.