A combustion synthesis method was developed for synthesis of AlN powder. Al powder and small amounts of NH4Cl were thoroughly mixed and placed in low-melting-point containers made of a thin, perforated aluminum sheet. The combustion reaction was ignited by heating the top surface of the powder stack, and the aluminum container was converted completely to AlN during the combustion reaction. High product yields were obtained under N2 pressures of 0.2-0.5 MPa. The product was composed of a dense outer portion and a loose inner portion. Effects of several process parameters on the product yield were investigated and discussed.
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