Porous has been formed in samples when mullite whiskers are prepared by firing compacts of high-aluminum fly ash and ammonium aluminum sulfate hydrate with a small amount of sodium dihydrogen phosphate and SiO2 at high temperature for 4 h. The effects of the particle size of fly ash, the firing temperature, and the content of sodium dihydrogen phosphate on the porous structure and the formation of whiskers are discussed. The results show that the smaller the particle size of fly ash, the more uniform porous in sample after fired, which is more conducive to the nucleation of mullite whiskers. Additionally, the amount of whiskers formation increased significantly with the firing temperature increasing, nonetheless, the pore size of porous reduced and the aspect ratio of whiskers gradually increased by reducing the content of sodium dihydrogen phosphate; owing to the reduction of glass melt in the matrix, the Al2O3/SiO2 ratio of the formed mullite whiskers gradually decreased. Thus, in order to obtain mullite whiskers self-reinforcement porous ceramics with the relatively low cost and no pollution to the environment, through the above preparation process, the addition amount of sodium dihydrogen phosphate and calcination temperature should be properly controlled.
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