Rapid solid-state synthesis of refractory materials

Abstract

A process for producing a refractory material having the form TB.sub.o, e.g. zirconium nitride (ZrN), includes a first step of mixing a first salt having the form TX.sub.n, e.g. zirconium tetrachloride (ZrCl.sub.4) and a second salt having the form A.sub.m B, e.g. lithium nitride (Li.sub.3 N) in a ratio of n/m in a container. The process also includes a second step of igniting the mixture of the first and second salts, e.g. ZrCl.sub.4 and Li.sub.3 N, whereby the refractory material, e.g. ZrN, is produced along with byproducts having forms nAX and (n/m-o)B, e.g. 4LiCl and (1/6)N.sub.2, respectively. The process further includes a third step of separating the refractory material from the byproducts by solvent extraction. The stoichiometric ratio of the second salt to the first salt is n/m, e.g. 4/3. T is selected from the group consisting of transition metals, e.g. zirconium, and tetrelides, i.e. carbon, silicon, germanium, tin and lead. X is selected from the halide group consisting of fluorine, chlorine, bromine and iodine. A is selected from the group consisting of alkali metals, i.e. lithium, sodium, potassium, rubidium and cesium, and alkaline earth metals, i.e. beryllium, magnesium, calcium, strontium and barium. B is a base selected from the group consisting of pnictides, i.e. nitrogen, hosphorus, arsenic, antimony and bismuth, and tetrelides, i.e. carbon, silicon, germanium, tin and lead, m and n are integers and o is a fraction, e.g. 3/3=1.