On synthesis of Fe₂SiO₄/SiO₂ and Fe₂O₃/SiO₂ composites through sol–gel and solid-state reactions

Major processing factors in forming Fe₂SiO₄/SiO₂ and Fe₂O₃/SiO₂ powders via sol–gel synthesis followed by solid-state reactions are investigated. The results clearly indicate that the chemical compositions of the precursors, the ratio of the precursors, the nature of the catalyst used, and the gas atmosphere during solid-state reactions can all affect the outcome of the reaction product(s). The formation of Fe₂SiO₄/SiO₂ is enhanced by using the precursor iron(III) acetylacetonate as the Fe source with the precursor ratio of iron(III) acetylacetonate to tetraethyl orthosilicate being 1:1 and the addition of formic acid. Otherwise, crystalline Fe and Fe₃C are formed in place of Fe₂SiO₄. By altering the gas atmosphere during solid-state reactions from argon to oxygen, the reaction products change from Fe₂SiO₄/SiO₂ to Fe₂O₃/SiO₂. All of the observed phenomena can be rationalized via the degree of mixing of the Fe–O and Si–O domains at the molecular level in the gel network during sol–gel reactions and the presence of a reducing or oxidizing atmosphere during the solid-state reaction.