Molten salt synthesis of orthorhombic CrB and Cr2AlB2 ceramics

High-purity and fine CrB powders are firstly synthesized from Cr and B powders in (Na, K)Cl molten salt at 850 °C for 2 h. Then the as-achieved CrB powders are used as precursors to synthesize homogeneous and size-controlled Cr₂AlB₂ powders in (Na, K)Cl molten salt at 900 °C for 2 h. Additionally, the formation mechanisms of CrB and Cr₂AlB₂ in (Na, K)Cl molten salt are also investigated. Results show that the Cr atom, formed by disproportionation of Cr²⁺ ions in molten salt, reacts in-situ with B powders to form CrB. For the formation of Cr₂AlB₂, Al and CrB migrate mutually and assemble firstly in the molten salt, and then Al intercalates into CrB to generate Cr₂AlB₂.     

Synthesis of group IV and V metal diboride nanocrystals via borothermal reduction with sodium borohydride

The synthesis of early transition nanocrystals using NaBH₄ and the respective metal oxides at atmospheric pressure was studied at temperatures between 400 and 1000°C. Reaction products were analyzed by x‐ray diffraction, the crystallite size was determined after Rietveld refinement of diffraction patterns, while the morphology was analyzed by scanning and transmission electron microscopy. For all the investigated systems the lowest temperature to complete the synthesis was 700°C and the reaction occurred in three subsequent steps: (i) decomposition of NaBH₄, (ii) formation of crystalline ternary species Na–M–O and Na–B–O, (iii) conversion of intermediary species to MB₂ and NaBO₂. Syntheses carried out at T > 700°C only caused coarsening of the powders. The synthetized boride powders had the morphology of highly agglomerated nanocrystals. TiB₂ had a specific surface area of 33.5 m²/g and crystallite diameter of 12 nm. Both ZrB₂ and HfB₂ had a platelet‐like morphology with crystallite diameter around 45 nm and specific surface area of 25.0 and 36.4 m²/g, respectively. Finally, NbB₂ and TaB₂ powders had a crystallite diameter around 5 nm with specific surface area of 21.1 and 11.4 m²/g, respectively. The goal of this synthesis is the use of cheap raw materials and moderate temperature conditions.     

Catalyzed synthesis of rhombohedral boron nitride in sodium chloride molten salt

Although a variety of methodologies/techniques have been used to prepare h-BN powders with different sizes and purities, only a few methods are reported to synthesize r-BN. In this work, highly crystalline r-BN with a purity of 94 wt% was successfully synthesized in sodium chloride molten salt using Na₂B₄O₇ and Mg powders as starting materials at 1000 °C in nitrogen atmosphere. The sodium (Na) produced by the reaction of Mg and Na₂B₄O₇ has a positive effect on the formation r-BN in the molten salt. The effect of Na as a crystallization promoter to produce crystallized r-BN was demonstrated by heating a mixture of t-BN and Na at 800–1200 °C. The formation, dissolution and evaporation of Na in the melt was discussed. The influence of synthesis temperature on the phase composition and morphology of the final products in the melt was also investigated. The possible formation mechanism of r-BN is proposed.     

Synthesis of Ti3SiC2 coatings onto SiC monoliths from molten salts

Coatings with composition close to Ti₃SiC₂ were obtained on SiC substrates from Ti and Si powders with the molten NaCl method. In this work, the growth of coatings by reaction in the salt between monolithic SiC substrates and titanium powder is obtained between 1000 and 1200 °C. At 1000 °C, a coating of 8 µm thickness is formed in 10 h whereas a thin coating of 0.5 µm has been grown in 2 h. A lack in silicon was first found in the coatings prepared at 1100 and 1200 °C. For these temperatures, the addition of silicon powder in the melt had a favorable effect on the final composition, which is found very close to the composition of Ti₃SiC₂. The reaction mechanism implies the formation of TiC_x layers in direct contact with the SiC substrate and the presence of more or less important quantities of Ti₃SiC₂ and Ti₅Si₃C_x in the upper layers.     

Neutron adsorption performance of Dy2TiO5 materials obtained from powders synthesized by the molten salt method

Dy₂TiO₅ powders were synthesized by molten salt and solid-state methods. The influences of molten medium on phase compositions and microstructures were analyzed. The addition of molten salt lowered significantly the synthesis temperature and resulted in uniform powders. Green bodies compacted from the prepared powders were pressureless sintered at 1600 °C. Sinterability, mechanical properties and neutron absorption performance of the sintered pellets were studied. Results showed that molten salt synthesis resulted in materials with higher fracture toughness and bending strength, excellent hardness and neutron adsorption performance compared to the solid-state process. The neutron absorption rate reached 86.6% for 8 cm thick pellets.     

Low-temperature molten salt synthesis of YAlO3 powders assisted by an electrochemical process

YAlO₃ (YAP) powders were successfully synthesized by a unique molten salt method, where YAP precursor was prepared by an electrochemical method at room temperature, followed by calcining it at a temperature of not exceeding 400 °C for 8 h using LiNO₃ as the molten salt medium. XRD analysis and TEM observation show that well-crystallized YAP powders can be obtained at 400 °C for a holding time of 8 h with 1:16 ratio of YAP precursor to LiNO₃ by weight. Greatly reduced temperature of forming YAP should be attributed to the incorporation of LiNO₃ salt in preparing process.     

Dielectric properties of nano-sized Ba0.7Sr0.3TiO3 powders prepared by spray pyrolysis

Nano-sized Ba_0.7Sr_0.3TiO₃ powders are prepared by post-treatment of the precursor powders with hollow and thin wall structure at temperatures between 900 and 1100 °C. Ethylenediaminetetraacetic acid and citric acid improve the hollowness of the precursor powders prepared by spray pyrolysis. The mean sizes of the powders post-treated at temperatures of 900, 1000 and 1100 °C are 42, 51 and 66 nm, respectively. The densities of the Ba_0.7Sr_0.3TiO₃ pellets obtained from the powders post-treated at 900, 1000 and 1100 °C are each 5.36, 5.55 and 5.38 g cm^?3 at a sintering temperature of 1300 °C. The pellet obtained from the powders post-treated at 1000 °C has higher maximum dielectric constant than those obtained from the powders post-treated at 900 and 1100 °C.     

Effects of calcination temperature on structure and magnetic properties of pure FeCo2O4 powders

A series of FeCo₂O₄ powders was initially synthesized using a hydrothermal method and subsequently calcined at various temperatures to produce the final product. Pure phase FeCo₂O₄ powders can only be formed in the temperature range of 950–1050 °C. In this work, we study the cation occupation, cation valence, bond length and bond angle changes of the pure phase FeCo₂O₄ powders formed in such a narrow temperature range. Octahedral lattice distortion in the pure phase FeCo₂O₄ samples has been observed. More tetrahedral Fe³⁺ and octahedral Co²⁺ are excited and exchanged their sites as the calcination temperature increases from 950 °C to 1000 °C, and part of Co³⁺ ions are reduced to Co²⁺ in the sample calcined at 1050 °C. The structure of the sample calcined at 1000 °C is close to that of the ideal FeCo₂O₄ spinel. Magnetic measurements show that ferrimagnetism and anti-ferromagnetism coexist in the pure phase FeCo₂O₄ samples. Interaction changes between ferrimagnetism and antiferromagnetism caused by the structural changes of the samples have been studied. Due to the pinning of the local anti-ferromagnetism to ferrimagnetism in the sample, the sample shows a Barkhausen jump below 150 K. As the measurement temperature increases further, the system enters into a reentrant spin glass state.     

Columnar and DVC-structured thermal barrier coatings deposited by suspension plasma spray: high-temperature stability and their corrosion resistance to the molten salt

High-temperature stability of SPS YSZ coatings with the columnar and deep vertically cracked (DVC) structures and their corrosion resistance to 56 wt% V₂O₅+44 wt% Na₂SO₄ molten salt mixture were investigated. Both the columnar and DVC-structured YSZ coatings were sintered at 1000 °C, but a significant increase in porosity in combination with significant reductions in Vickers’ hardness and Young's modulus were observed at the temperatures from 1200 °C to 1400 °C. The DVC-structured YSZ coating exhibited superior corrosion resistance against the molten salt mixture attack to the columnar-structured one due to its higher density behaving as a sealing protective top layer at 950 °C.     

Low‐Temperature Sintering of β‐Spodumene Ceramics Using Li2O–GeO2 as a Sintering Additive

Low‐temperature sintering of β‐spodumene ceramics with low coefficient of thermal expansion (CTE) was attained using Li₂O–GeO₂ sintering additive. Single‐phase β‐spodumene ceramics could be synthesized by heat treatment at 1000°C using highly pure and fine amorphous silica, α‐alumina, and lithium carbonate powders mixture via the solid‐state reaction route. The mixture was calcined at 950°C, finely pulverized, compacted, and finally sintered with or without the sintering additive at 800°C–1400°C for 2 h. The relative density reached 98% for the sample sintered with 3 mass% Li₂O–GeO₂ additive at 1000°C. Its Young's modulus was 167 GPa and flexural strength was 115 MPa. Its CTE (from R.T. to 800°C) was 0.7 × 10^?6 K^?1 and dielectric constant was 6.8 with loss tangent of 0.9% at 5 MHz. These properties were excellent or comparative compared with those previously reported for the samples sintered at around 1300°C–1400°C via melt‐quenching routes. As a result, β‐spodumene ceramics with single phase and sufficient properties were obtained at about 300°C lower sintering temperature by adding Li₂O–GeO₂ sintering additive via the conventional solid‐state reaction route. These results suggest that β‐spodumene ceramics sintered with Li₂O–GeO₂ sintering additive has a potential use as LTCC for multichip modules.     

Fracture and property relationships in the double diboride ceramic composites by spark plasma sintering of TiB2 and NbB2

Bulk titanium diboride–niobium diboride ceramic composites were consolidated by spark plasma sintering (SPS) at 1950°C. SPS resulted in dense specimens with a density exceeding 98% of the theoretical density and a multimodal grain size ranging from 1 to 10 μm. During the SPS consolidation, the pressure was applied and released at 1950 and 1250°C, respectively. This allowed obtaining a two-phase composite consisting of TiB₂ and NbB₂. For these ceramics composites, we evaluated the flexural strength and fracture toughness and room and elevated temperatures. Room-temperature strength of thus produced bulks was between 300 and 330 MPa, at 1200°C or 1600°C an increase in strength up to 400 MPa was observed. Microstructure after flexure at elevated temperatures revealed the appearance of the needle-shape subgrains of NbB₂, an evidence for ongoing plastic deformation. TiB₂–NbB₂ composites had elastic loading stress curves at 1600°C, and at 1800°C fractured in the plastic manner, and strength was ranged from 300 to 450 MPa. These data were compared with a specimen where a (Ti,Nb)B₂ solid solution was formed during SPS to explain the behavior of TiB₂–NbB₂ ceramic composites at elevated temperatures.     

Crystallization behavior of CMAS and NaVO3+CMAS mixture and its potential effect to thermal barrier coatings corrosion

Calcium-magnesium-alumina-silicate (CMAS) and molten salt corrosion pose great threats to thermal barrier coatings (TBCs), and recently, a coupling effect of CMAS and molten salt has been found to cause even severer corrosion to TBCs. In this study, the crystallization behavior of CMAS and CMAS+NaVO₃ is investigated for potentially clarifying their corrosion mechanisms to TBCs. Results indicated that at 1000 °C and 1100 °C, CMAS was crystallized to form CaMgSi₂O₆, while at 1200 °C, the crystallization products were CaMgSi₂O₆, CaSiO₃ and CaAl₂Si₂O₈. The introduction of NaVO₃ in CMAS reduced the crystallization ability, and as the NaVO₃ content increased, glass crystallization occurred at a lower temperature, with crystallization products mainly consisting of CaAl₂Si₂O₈ and CaMgSi₂O₆. At 1200 °C, CMAS+10 wt% NaVO₃ was in a molten state without any crystallization, which suggested that NaVO₃ addition in CMAS could reduce its melting point, indicating enhanced penetration ability in TBCs and thus increased corrosiveness.     

Rapid low temperature synthesis of a titanate pyrochlore by molten salt mediated reaction

Ytterbium titanate pyrochlore, Yb₂Ti₂O₇, was prepared by molten salt mediated synthesis (MSS) from titanium oxide (TiO₂) and ytterbium oxide (Yb₂O₃) reagents. Potassium and sodium chloride mixtures were used as the molten salt medium and the effects of salt to reagent ratio, salt composition, synthesis temperature, reaction time, and TiO₂ particle size were explored. Synthesis temperatures and times required for formation of single phase Yb₂Ti₂O₇ were found to be lower than those required for solid state synthesis (SSS). Whereas MSS synthesis of single phase Yb₂Ti₂O₇ was achieved with micron-sized powders after a single reaction at 1200 °C for 1 h, SSS with micron-sized powders required an extended reaction time of 36 h at 1350 °C. Yb₂Ti₂O₇ micron-sized powder prepared by MSS showed similar particle size and morphology to that of the TiO₂ precursor demonstrating a template growth mechanism. However, the use of TiO₂ nano-sized powder changed the dominant synthesis mechanism from template growth to dissolution–precipitation and facilitated synthesis of near single phase Yb₂Ti₂O₇ at the remarkably low temperature of 700 °C in only 1 h. The potential application for lanthanide and actinide immobilisation from molten salt reprocessing wastes was demonstrated by preparation of Yb₂Ti₂O₇ by molten salt mediated synthesis from TiO₂ and ytterbium chloride (YbCl₃) reagents.     

Mechanical properties of in situ synthesized mullite-based composite ceramics with three-dimensional network structure

Needle-like nanocrystalline mullite powders were prepared through the molten salt process at the temperature of 900°C using coal gangue as raw material. Then, mullite-based composite ceramics were prepared by a conventional solid-state reaction between in situ synthesized mullite and Al₂O₃ powders. Effects of Al₂O₃ content and sintering temperatures on phase compositions, microstructure, and mechanical properties of the mullite-based composite ceramics were also studied. The results show that mullite content productivity increase from 72% to 95%, as the sintering temperature increased from 1480°C to 1580°C, which led to the improvement in the bulk density and flexural strength of the samples. The three-dimensional interlocking structure for mullite-based composite ceramics was obtained by the in situ solid-state reaction process. The maximum bulk density, flexural strength, and fracture toughness for the sample with 15 wt% Al₂O₃ content are 2.48 g/cm³, 139.79 MPa, and 5.62 MPa··m^1/2, respectively, as it was sintered at the temperature of 1560°C for 3 h. The improved mechanical properties of mullite-based composite ceramics maybe ascribed to good densification and increased mullite phase content, as well as to the in situ three-dimensional network structure. Therefore, the results would provide new ideas for high-value utilization of coal gangue.     

Molten salt synthesis of zinc aluminate powder

ZnAl₂O₄ powder was synthesised by reacting equimolar ZnO and Al₂O₃ powders in alkaline chlorides (LiCl, NaCl or KCl). Formation of ZnAl₂O₄ started at about 700 °C in LiCl and 800 °C in NaCl and KCl. With increasing temperature, the amounts of ZnAl₂O₄ in the resultant powders increased with a concomitant decrease of ZnO and Al₂O₃. ZnAl₂O₄ powder was obtained by water-washing the samples heated for 3 h at 1000 °C (LiCl) or 1050 °C (NaCl and KCl). ZnAl₂O₄ formed in situ on Al₂O₃ grains from the surface inwards. The synthesised ZnAl₂O₄ grains retained the size and morphology of the original Al₂O₃ powders, indicating that a template formation mechanism dominated formation of ZnAl₂O₄ by molten salt synthesis.     

Microstructure evolution and hot corrosion mechanisms of Ba2REAlO5 (RE = Yb,Er, Dy) exposed to V2O5 + Na2SO4 molten salt

Ba₂REAlO₅ (RE?=?Dy, Er, Yb) powders were synthesized by a solid state reaction method, followed by cold pressing and sintering to produce pellets for hot corrosion tests. When exposed to V₂O₅?+?Na₂SO₄ molten salt at 900?°C and 1000?°C for 4?h and 20?h, REVO₄, Ba₃(VO₄) ₂ and BaAl₂O₄ formed as corrosion products due to chemical interactions between the ceramics and the molten salt, which were temperature and time independent. After the hot corrosion tests at 1000?°C, continuous, dense reaction layers with a thickness of ～80?μm formed on the sample surfaces, which had an effective function on suppressing further penetration of the molten salt. The hot corrosion mechanisms of Ba₂REAlO₅ are proposed based on Lewis acid-base rule, phase diagrams and thermodynamics. From a thermodynamics perspective, the molten salt directly reacting with Ba₂REAlO₅ is difficult compared with Yb₂O₃, Al₂O₃ and BaO.     

Molten Salt Synthesis of Bismuth Ferrite Nano‐ and Microcrystals and their Structural Characterization

Bismuth ferrite nano‐ and microcrystals were prepared by a facile molten salt technique in two kinds of molten‐salt‐based systems (NaCl–KCl and NaCl–Na₂SO₄). In the NaCl–KCl salt system, a systematic study indicating the effects of process parameters (e.g., calcination temperature, holding time as well as the molten salt ratios) on the bismuth ferrite formation mechanism and structural characteristics is reported. The results show that almost pure phase BiFeO₃ powders with minimum impurity phase of Bi₂Fe₄O₉ were synthesized at temperatures of 700°C–800°C, whereas high calcination temperature (e.g., 900°C) resulted in the formation of almost pure phase Bi₂Fe₄O₉ powders. The prolonged holding time increased the particle size via the Ostwald ripening mechanism; however, there was little effect on the particle morphology. Similar phenomenon occurred as increasing the molten salt ratios. In the NaCl–Na₂SO₄ salt systems, it is found that low NP‐9 (nonylphenyl ether, NP‐9) surfactant content (0–5 mL) led to the formation of almost pure phase BiFeO₃ powders, whereas high NP‐9 surfactant content (e.g., 20 mL) resulted in pure phase Bi₂Fe₄O₉ powders. The average particle size of the BiFeO₃ powders was decreased as increasing the NP‐9 surfactant content, whereas their morphologies did not change significantly. Because of the simplicity and versatility of the approach used, it is expected that this methodology can be generalized to the large‐scale preparation of other important transitional metal oxides with controllable sizes and shapes.     

Assessment of bismuth oxide-based electrolytes for composite gas separation membranes

Oxide + salt composites can be used in CO₂ and NO_x separation membranes, where high oxide-ion conductivity is crucial to improve performance. Pursuing this goal, the stability of three different bismuth oxide-based electrolytes (Cu + V, Y and Yb-doped) against molten alkali carbonates (Li, Na, K) or nitrates (Na, K) was tested firing them in the 450–550 °C temperature range, and with endurance tests up to 100 h. A well-known ceria-based composite was used as reference (CGO - Ce_0.9Gd_0.1O_1.95). Oxides and composites were studied by X-ray diffraction, scanning electron microscopy and impedance spectroscopy (in air, 140–650 °C temperature range). Bi₂Cu_0.10V_0.90O_5.35 easily reacts with molten salts. Bi_0.75Y_0.25O_1.5 and Bi_0.75Yb_0.25O_1.5 have higher stability against molten carbonates and complete stability against molten nitrates. The Y-doped oxide stability against the molten carbonates was enhanced changing the molten salt composition (Y₂O₃ additions) and using lower firing temperatures. Above all, composites based on Y or Yb-doped Bi₂O₃ with molten alkali nitrates showed impressive 6× or 3× higher electrical conductivity at 290 °C, in air (4.88 × 10⁻² and 2.41 × 10⁻² S cm⁻¹, respectively) than CGO-based composites (7.72 × 10⁻³ S cm⁻¹), qualifying as promising materials for NO_x separation membranes.     

Molten salt attack on t′ yttria-stabilised zirconia by dissolution and precipitation

Degradation due to molten salt attack is one of the failure mechanisms of thermal barrier coatings. Thermochemical attack of the salt mixture Na₂SO₄–30 mol% NaVO₃ on ZrO₂–8 mol% YO_1.5 (8YSZ) at 950 °C was studied by two types of experiments. Sintered compacts were exposed to 25 mg cm^?2 salt dosage for up to 96 h. In the other set of experiments, 10–35 wt.% 8YSZ powder was mixed with the salts to study the dissolution of 8YSZ in the molten salt. The role of volatile losses was also examined. The results show that more than 25 wt.% 8YSZ dissolves in the sulphate-vanadate melt at 950 °C, followed by slow reactions to form YVO₄ and NaYV₂O₇ at 950 °C. The unreacted Y₂O₃ and monoclinic ZrO₂ precipitate out separately during rapid cooling (～300 °C/min). Slow cooling at ～3 °C/min leads to the formation of ZrOS apart from ZrO₂ and Y₂O₃.     

The effects of raw materials particle size and salt type on formation of nano-CaZrO3 from molten salts

Nano-CaZrO₃ was successfully synthesized at 800 °C using the molten-salt method, and the effects of salt type and raw materials particle size on the formation of CaZrO₃ were investigated. Na₂CO₃, CaCl₂, nano-ZrO₂ and micro-ZrO₂ were used as starting materials. On heating, Na₂CO₃ reacted with CaCl₂ to form NaCl and in situ CaCO₃. Na₂CO₃–NaCl molten eutectic salt provided a liquid medium for reaction of CaCO₃ and ZrO₂ to form CaZrO₃. The results demonstrated that in both nano- and micro-ZrO₂ inclusive samples, CaZrO₃ started to form at about 700 °C and that, after the temperature was increased to 1000 °C, the amounts of CaZrO₃ in the resultant powders increased with a concomitant decrease in CaCO₃ and ZrO₂ contents. After washing with hot-distilled water, the samples containing nano- and micro-ZrO₂ heated for 3 h at 800 °C and 1000 °C, were single-phase CaZrO₃ with 70–90 nm and 400–450 nm particle size, respectively. Also, the synthesis process was completed in lower temperatures using eutectic salts. Furthermore, the synthesized CaZrO₃ particles retained the size and morphology of the ZrO₂ powders, which indicated that a template formation mechanism dominated the formation of CaZrO₃ by molten-salt synthesis.