Effects of Ifon clay and sintering temperature on the phase development and physico-mechanical properties of mullite-carbon ceramic composite was investigated. Powders of Ifon clay, kaolin from Okpella and graphite of known mineralogical composition were thoroughly blended in a ball mill for 3 hrs at a speed of 60 rev/min using a predetermined ratio. From the blended powders, standard samples were produced by uniaxial compression. This was followed by sintering in an electric furnace at 1400 oC, 1500 oC and 1600 oC for 1 hr. The sintered samples were characterized for various physical and mechanical properties. It was observed that; Ifon clay addition to the sample favours the formation of microcline in preference to mullite at temperature between 1400 oC and 1500 oC. As the sintering temperature increases to 1600 oC there is the formation of mullite phase and pores. These pores allowed the graphite content of the samples to be oxidized leading to reduction in the graphite content of the samples. The addition of Ifon clay improved on some of the mechanical properties of the samples like the cold crushing strength and Young's Modulus compared to the earlier reported samples without Ifon clay. The sample with optimum physico-mechanical is considered to be the sample sintered at 1400 oC.

Keywords: Sintering temperature, Mullite, Graphite, Ceramic composite, Phase evolution.