Synthesis of β -SiAlON whiskers: dependence of uniform morphology upon preparation conditions

β-SiAlON whiskers with uniform morphology were prepared using reaction sintering method under different conditions. The effect of preparing conditions on the morphology of β-SiAlON whiskers was systematically studied by SEM, XRD, TEM and HRTEM. The results showed that single crystalline β-SiAlON whiskers with uniform morphology were successfully fabricated at 1773 K for 6 h under flowing nitrogen atmosphere. The well synthesised whiskers were of several hundreds of nanometres in diameter and a few hundreds of micrometres in length. Although the morphology and its size distribution are mainly determined by the reaction temperature and holding time, they can also be tailored by controlling the reaction atmosphere. The ratio of staring materials has no significant influence on the morphology of β-SiAlON whiskers. The growth of β-SiAlON whiskers follows a vapour–solid mechanism, and the formation of the belt-like whiskers is attributed to an anisotropic growth at the early nucleation/growth stage.