The sol–gel transition of mullite spinning solution in relation to the formation of ceramic fibers

Continuous mullite ceramic fibers were fabricated by a sol–gel dry spinning technique. The sol was prepared from an aqueous solution of aluminum nitrate (AN), aluminum isopropoxide (AIP) and tetraethylorthosilicate (TEOS). The sol–gel transition was investigated by measuring the volume, the solid content, the viscosity and the rheological properties of the solution. Shear viscosity η of the mullite sol varied dynamically with concentrating time and temperature. Combine size analysis of sol particles and TEM analysis on this basis, the growth character of sol particles agglomeration and its structural evolution were discussed. By adjusting the temperature, the gelling degree could stabilize at a certain value and the sol–gel transition could be transferred to the spinning line. Continuous fibers were spun from such sols immediately before gelling in a laboratory dry spinning apparatus. The spinneret contained thirty circular holes, each having a diameter of 0.2 mm. The temperature inside the spinning channel was 100–120 °C, the winding speed was 100–300 m/min. Sintering of the precursor fibers at 1,100 °C yields crack-free mullite ceramic fibers.