The effects of green density as an experimental parameter in influencing the crystallization of an amorphous silica layer coated on the surface of α‐alumina powder particles and the subsequent reaction of crystalline cristobalite and alumina to form mullite have been investigated. Green compacts consisting of alumina powder particles coated with an amorphous silica layer were fabricated using both a conventional uniaxial die pressing and rotary forging at room temperature, resulting in various green densities from 15% to 68% theoretical density. It has been shown that both the crystallization temperature of the amorphous silica layer coated on the surface of alumina powder particles and the subsequent mullitization temperature are lowered in the highly compacted materia