Mullite ceramics were fabricated at relatively low sintering temperatures (1500–1550°C) from recycled flyash and bauxite with MgO addition as raw materials. The densification behavior was investigated as function of magnesia content and sintering temperature. The results of thermal analysis, bulk density and pore structure indicate that MgO addition effectively promoted sintering, especially above 1450°C. Due to the presence of large interlocked elongated mullite crystals above 1450°C, associated with enhanced densification, an improvement in mechanical strength was obtained for the samples containing magnesia. The addition of magnesia slightly decreases the LTEC at 1300°C due to the formation of low-expansion α-cordierite, but slightly increases the LTEC above 1400°C due to the formation of high expansion corundum and MgAl₂O₄ spinel.