A novel preparation of Zr–Si intermetallics by electrochemical reduction of ZrSiO4 in molten salts

Abstract

A method of controllably preparing Zr–Si intermetallics by the electrochemical reduction of ZrSiO₄ and ZrSiO₄–SiO₂ mixed powders in molten CaCl₂–NaCl at 800 °C is developed. The final product composition can be controlled by adjusting the molar ratio of Si to Zr in the starting material, and ZrSi, ZrSi₂ and their mixture were obtained by this process. The reduction pathway of ZrSiO₄ and SiO₂ to Zr–Si intermetallics involves several calcium-containing intermediate phases, such as CaSiO₃, Ca₂SiO₄, and calcia-stabilized zirconia (CSZ).