The reaction-bonded aluminum oxide (RBAO) process utilizes the oxidation of attrition-milled Al/Al2O3/ZrO2 powder compacts, that are heat treated in air, to make alumina-based ceramics. A simultaneous mass and energy balance has been used to model the propagation of the ignition front that has been observed during reaction-bonding. The model is used to determine conditions under which ignition can be avoided. (C) 2001 Acta Materialia Inc. Published by Elsevier Science Ltd. All rights reserved.