Solid state tialite formation: unveiling the impact of high energy milling and two-step sintering on its properties

Abstract The objective of this study was to synthesize and partially stabilize tialite (β-Al 2 TiO 5 ), a refractory ceramic material recognized for its high thermal shock resistance, low thermal conductivity, and low wettability with molten non-ferrous metals. This was accomplished by combining high-energy milling with a two-step sintering approach to promote a fine-grained microstructure and controlled porosity. Three Al 2 O 3 :TiO 2 molar ratios were investigated (55:35, 45:45, and 35:55), while maintaining a fixed addition of 10 mol.% MgO as a stabilizing agent. The results demonstrated that the composition with excess Al 2 O 3 exhibited superior densification and mechanical performance compared to the other ratios. The optimized specimens presented high relative density (3.19 ± 0.02 g cm −3 , 84.08 % relative density), low apparent porosity (05.50 ± 0.04 %), great tensile strength (11.17 MPa), and a refined microstructure with an average grain size below 2 μm. These findings highlight the effectiveness of combining high-energy milling and two-step sintering to produce stabilized tialite ceramics with enhanced structural integrity, providing a promising route for advanced refractory applications.