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

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).

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