RF Thermal Plasma Synthesis of Ultrafine ZrB₂-ZrC Composite Powders

Ultrafine ZrB₂-ZrC composite powders were synthesized via a radiofrequency (RF) thermal plasma process. Numerical simulation and thermodynamic analysis were conducted to predict the synthesis process, and experimental work was performed accordingly to demonstrate its feasibility. The as-prepared samples were characterized by XRD, FESEM, particle size analyzer, nitrogen/oxygen analyzer, Hall flowmeter, and the Brunner-Emmet-Teller (BET) measurements. The thermodynamic analysis indicated that ZrB₂ was preferentially generated, rather than ZrC, and numerical simulation revealed that the solid raw materials could disperse well in the gaseous reactants, and experimental work showed that free carbon particles were easily removed from the products and the elements of Zr, B, C, and O exhibited a uniform distribution. Finally, ZrB₂-ZrC composite powders with a particle size of about 100 nm were obtained, the surface area of which was 32.15 m²/g and the apparent density was 0.57 g/cm³.