Mullite fibres were synthesised from a mixture of aluminium, aluminium chloride and acidic silica solutions as monophasic salts using a sol–gel technique. The viscosity and rheological behaviour of the mullite precursor sol were examined. Mullite fibres were synthesised using both conventional and microwave sintering techniques. The samples were characterised by X-ray diffraction and scanning electron microscopy. Pure mullite fibres were synthesised by microwave sintering at a relatively low temperature of 1200°C. The grain size of the fibre samples sintered using the microwave technique was finer than that produced by conventional sintering. These results show that microwave sintering is a promising technique for processing mullite fibres.
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