Abstract

A two-step carbothermal reduction process produced zirconium carbide particles with less aggregation and smaller ZrC grains than those produced by one-step reduction. Reduction at 1500°C for 10min (1st step) and then at 1300°C for 30min (2nd step) produced significantly smaller agglomerations (1–8μm) and particles (33nm) than those produced using other reduction processes, which were 2–200μm and >1μm, respectively. The first high-temperature step allowed effective reduction, while the subsequent cooler step inhibited grain growth and agglomeration. The resulting ZrC particles showed a stoichiometric composition of ZrC0.97 through control of the carbon content. A sintered W–ZrC composite made using the two-step-reduced ZrC was harder and showed a more homogeneous dispersion of ZrC in the tungsten matrix than a composite made using one-step sintered ZrC.

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