The influence of attrition milling on the thermal decomposition of kyanite (Al2O3·SiO2) to mullite (3Al2O3·2SiO2) and SiO2, and its subsequent sintering, was studied. A commercial kyanite was attrition‐milled for times up to 12 h. Dilatometry confirmed that as‐received unmilled kyanite decomposes between 1300° and 1435°C. The decomposition reaction is slow initially and accelerates during the later stages until about one‐half of the decomposition occurs in the last 35°C. For the attrition‐milled kyanite, the onset decomposition temperature decreases, the transformation temperature interval is reduced, and both the decomposition reaction and subsequent sintering are accelerated. A dense microstructure of fine equiaxed mullite grains in the 1 μm size range, evenly dispersed in a glassy matrix, is obtained by sintering the attrition‐milled kyanites. These results are explained in terms of the energy accumulated during attrition milling, a reduction of the milled kyanite particle size, and the presence of a liquid phase during sintering.
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