The present study investigates the preparation of homogeneous and dense Mo(AlxSi1-x)2(x=0,0.05,0.1,0.15,0.2) powders using the self-propagating high-temperature synthesis (SHS) technique, followed by the fabrication of Al-modified MoSi2 ceramics using spark plasma sintering (SPS) technology. The microstructural evolution and high-temperature oxidation resistance of the ceramics are observed. The results indicate that after oxidation, MoSi2 is mainly composed of MoSi2 phase and SiO2 phase. Upon addition of Al, Mo(AlxSi1-x)2(x=0,0.05,0.1,0.15,0.2) is primarily composed of MoSi2 phase, Al2O3 phase, and SiO2 phase. The partial substitution of Si with Al enhances the oxidation resistance of MoSi2. Because a protective alumina (Al2O3) film is formed through the substitution reaction at the original site. The SiO2 material generated by MoSi2 tends to evaporate and peel off in a reducing environment, whereas the alumina oxide skin formed by Mo(Al,Si)2 is stable and adherent. And during the oxidation process at 1500°C, Mo(Al0.05Si0.95)2 exhibits stable and slow mass gain. This is mainly attributed to the formation of a dense and intact Al2O3-SiO2 oxide film on the surface of Mo(Al0.05Si0.95)2 during oxidation, which suppresses the high-temperature diffusion of oxygen and effectively prevents further oxidation of the ceramic internally. Compared to the monolithic MoSi2 ceramic, the modified Mo(Al0.05Si0.95)2 ceramic exhibits less weight gain and a denser morphology, demonstrating relatively better high-temperature oxidation resistance.
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