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<p>Ultra-high-temperature ceramics play a crucial role in high-temperature applications, offering exceptional thermal stability, hardness, and strength. In this study, ZrC/SiC ceramic composites were directly synthesized from a natural zircon-bearing mineral via a thermal plasma arc-discharge-assisted carbothermic process. The formation of ZrC/SiC composites was investigated under varying milling durations and molar ratios of carbon. A mixture of milled ZrSiO<sub>4</sub> and carbon was processed in an argon and methane gas atmosphere at a plasma power of 15&#xa0;kW. The results indicate that a ZrSiO<sub>4</sub>/C molar ratio of 1:7 in an argon atmosphere and 1:4 in a methane atmosphere significantly influenced the formation of ZrC/SiC composites. The crystal structure, morphology, and elemental composition of the synthesized samples were analyzed using various characterization techniques. The plasma-prepared ZrC/SiC ceramic composite exhibited low thermal conductivity, higher hardness, and compressive strength. Additionally, thermodynamic free energy minimization analysis was employed to investigate the reaction mechanisms, phase formation, and stability of the ZrC/SiC composite at a 1:7 molar ratio. These insights provide a deeper understanding of the synthesis process and pave the way for further optimization of UHTC manufacturing.</p>

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Novel Thermal Plasma Methods for Scalable Synthesis of ZrC/SiC Ceramics via Carbothermic Reduction of Zircon-Bearing Minerals

  • 期刊论文

  • 发表日期：

    2026年6月3日

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  • L. Kumaresan,
  • S. Christan Sam,
  • G. Harish,
  • J. Venkatesan,
  • S. G. K. Manikandan,
  • K. Jayasankar

摘要

Ultra-high-temperature ceramics play a crucial role in high-temperature applications, offering exceptional thermal stability, hardness, and strength. In this study, ZrC/SiC ceramic composites were directly synthesized from a natural zircon-bearing mineral via a thermal plasma arc-discharge-assisted carbothermic process. The formation of ZrC/SiC composites was investigated under varying milling durations and molar ratios of carbon. A mixture of milled ZrSiO4 and carbon was processed in an argon and methane gas atmosphere at a plasma power of 15 kW. The results indicate that a ZrSiO4/C molar ratio of 1:7 in an argon atmosphere and 1:4 in a methane atmosphere significantly influenced the formation of ZrC/SiC composites. The crystal structure, morphology, and elemental composition of the synthesized samples were analyzed using various characterization techniques. The plasma-prepared ZrC/SiC ceramic composite exhibited low thermal conductivity, higher hardness, and compressive strength. Additionally, thermodynamic free energy minimization analysis was employed to investigate the reaction mechanisms, phase formation, and stability of the ZrC/SiC composite at a 1:7 molar ratio. These insights provide a deeper understanding of the synthesis process and pave the way for further optimization of UHTC manufacturing.