Mullite whiskers were successfully synthesized using coal fly ash, andalusite-sericite phyllite, NH 4 Al(SO 4 ) 2 ·12H 2 O and SiO 2 , with a slight addition of NaH 2 PO 4 ·2H 2 O by designing composition after sintered at different temperatures. The mullite whisker morphology, structure and formation mechanism were investigated by X-ray powder diffraction (XRD) and scanning electron microscopy (SEM). The results show that the forming temperature of pure mullite from andalusite-sericite phyllite is lower than that from coal fly ash owing to more silica glass phase. The mullite microcrystals begin to grow at approximately 1200 °C for andalusite-sericite phyllite and 1300 °C for coal fly ash, and both grow into long whiskers at around 1400 °C. With the prescription of Al 2 O 3 /SiO 2 molar ratio of 0.32, sintered at 1400 °C for 6 h and chemically leached with HF solution to remove glass matrix in the products, uniform mullite whiskers with 0.2 -0.5 μm (aspect ratio 30, prepared from high-aluminium coal fly ash) and 0.3 -3 μm (aspect ratio 10 -30, prepared from andalusite-sericite phyllite) in diameter can be well prepared.