Zirconium carbide ( Zr C) is an extremely

hard Hard may refer to: * Hardness, resistance of physical materials to deformation or fracture * Hard water, water with high mineral content Arts and entertainment * ''Hard'' (TV series), a French TV series * Hard (band), a Hungarian hard rock supe ...

refractory In materials science, a refractory material or refractory is a material that is resistant to decomposition by heat, pressure, or chemical attack, and retains strength and form at high temperatures. Refractories are polycrystalline, polyphase, ...

ceramic A ceramic is any of the various hard, brittle, heat-resistant and corrosion-resistant materials made by shaping and then firing an inorganic, nonmetallic material, such as clay, at a high temperature. Common examples are earthenware, porcelain ...

material, commercially used in

tool bit A tool bit is a non-rotary cutting tool used in metal lathes, shapers, and planers. Such cutters are also often referred to by the set-phrase name of single-point cutting tool, as distinguished from other cutting tools such as a saw or water j ...

s for cutting tools. It is usually processed by

sintering Clinker nodules produced by sintering Sintering or frittage is the process of compacting and forming a solid mass of material by pressure or heat without melting it to the point of liquefaction. Sintering happens as part of a manufacturing ...

Properties

It has the appearance of a gray metallic powder with cubic

crystal structure In crystallography, crystal structure is a description of the ordered arrangement of atoms, ions or molecules in a crystal, crystalline material. Ordered structures occur from the intrinsic nature of the constituent particles to form symmetric pat ...

. It is highly

corrosion Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engine ...

resistant. This Group IV interstitial transition-metal carbide is also a member of

ultra high temperature ceramics Ultra-high-temperature ceramics (UHTCs) are a type of refractory ceramics that that can withstand extremely high temperatures without degrading, often above 2,000 °C. They also often have high thermal conductivities and are highly resistan ...

or (UHTC). Due to the presence of metallic bonding, ZrC has a

thermal conductivity The thermal conductivity of a material is a measure of its ability to conduct heat. It is commonly denoted by k, \lambda, or \kappa. Heat transfer occurs at a lower rate in materials of low thermal conductivity than in materials of high thermal ...

of 20.5 W/m·K and an electrical conductivity (resistivity ~43 μΩ·cm), both of which are similar to that for zirconium metal. The strong covalent Zr-C bond gives this material a very high melting point (~3530 °C), high modulus (~440 GPa) and

hardness In materials science, hardness (antonym: softness) is a measure of the resistance to localized plastic deformation induced by either mechanical indentation or abrasion. In general, different materials differ in their hardness; for example hard ...

(25 GPa). ZrC has a lower

density Density (volumetric mass density or specific mass) is the substance's mass per unit of volume. The symbol most often used for density is ''ρ'' (the lower case Greek letter rho), although the Latin letter ''D'' can also be used. Mathematical ...

(6.73 g/cm³) compared to other carbides like WC (15.8 g/cm³), TaC (14.5 g/cm³) or HfC (12.67 g/cm³). ZrC seems suitable for use in

re-entry vehicle Atmospheric entry is the movement of an object from outer space into and through the gases of an atmosphere of a planet, dwarf planet, or natural satellite. There are two main types of atmospheric entry: ''uncontrolled entry'', such as the entr ...

rocket A rocket (from it, rocchetto, , bobbin/spool) is a vehicle that uses jet propulsion to accelerate without using the surrounding air. A rocket engine produces thrust by reaction to exhaust expelled at high speed. Rocket engines work entirely fr ...

scramjet A scramjet (supersonic combustion ramjet) is a variant of a ramjet airbreathing jet engine in which combustion takes place in supersonic airflow. As in ramjets, a scramjet relies on high vehicle speed to compress the incoming air forcefully ...

engine An engine or motor is a machine designed to convert one or more forms of energy into mechanical energy. Available energy sources include potential energy (e.g. energy of the Earth's gravitational field as exploited in hydroelectric power gen ...

s or supersonic vehicles in which low

densities Density (volumetric mass density or specific mass) is the substance's mass per unit of volume. The symbol most often used for density is ''ρ'' (the lower case Greek language, Greek letter Rho (letter), rho), although the Latin letter ''D'' ca ...

and high

temperature Temperature is a physical quantity that expresses quantitatively the perceptions of hotness and coldness. Temperature is measured with a thermometer. Thermometers are calibrated in various temperature scales that historically have relied o ...

s load-bearing capabilities are crucial requirements. Like most carbides of refractory metals, zirconium carbide is sub-stoichiometric, i.e., it contains carbon vacancies. At carbon contents higher than approximately ZrC_0.98 the material contains free carbon. ZrC is stable for a carbon-to-metal ratio ranging from 0.65 to 0.98. The group IVA metal carbides,

TiC A tic is a sudden, repetitive, nonrhythmic motor movement or vocalization involving discrete muscle groups.American Psychiatric Association (2000)DSM-IV-TR: Tourette's Disorder.''Diagnostic and Statistical Manual of Mental Disorders'', 4th ed., ...

, ZrC, and

SiC The Latin adverb ''sic'' (; "thus", "just as"; in full: , "thus was it written") inserted after a quoted word or passage indicates that the quoted matter has been transcribed or translated exactly as found in the source text, complete with any e ...

are practically inert toward attack by strong aqueous acids (HCl) and strong aqueous bases (NaOH) even at 100' C, however, ZrC does react with HF. The mixture of zirconium carbide and

tantalum carbide Tantalum carbides (TaC) form a family of binary chemical compounds of tantalum and carbon with the empirical formula TaC''x'', where ''x'' usually varies between 0.4 and 1. They are extremely hard, brittle, refractory ceramic materials with metall ...

is an important

cermet A cermet is a composite material composed of ceramic (cer) and metal (met) materials. A cermet can combine attractive properties of both a ceramic, such as high temperature resistance and hardness, and those of a metal, such as the ability to und ...

material.

Uses

Hafnium Hafnium is a chemical element with the symbol Hf and atomic number 72. A lustrous, silvery gray, tetravalent transition metal, hafnium chemically resembles zirconium and is found in many zirconium minerals. Its existence was predicted by Dmitri M ...

-free zirconium carbide and

niobium carbide Niobium carbide ( Nb C and Nb2C) is an extremely hard refractory ceramic material, commercially used in tool bits for cutting tools. It is usually processed by sintering and is a frequent additive as grain growth inhibitor in cemented carbides. It ...

can be used as refractory coatings in

nuclear reactor A nuclear reactor is a device used to initiate and control a fission nuclear chain reaction or nuclear fusion reactions. Nuclear reactors are used at nuclear power plants for electricity generation and in nuclear marine propulsion. Heat from nu ...

s. Because of a low neutron absorption cross-section and weak damage sensitivity under irradiation, it finds use as the coating of

uranium dioxide Uranium dioxide or uranium(IV) oxide (), also known as urania or uranous oxide, is an oxide of uranium, and is a black, radioactive, crystalline powder that naturally occurs in the mineral uraninite. It is used in nuclear fuel rods in nuclear rea ...

and

thorium dioxide Thorium dioxide (ThO2), also called thorium(IV) oxide, is a crystalline solid, often white or yellow in colour. Also known as thoria, it is produced mainly as a by-product of lanthanide and uranium production. Thorianite is the name of the minera ...

particles of

nuclear fuel Nuclear fuel is material used in nuclear power stations to produce heat to power turbines. Heat is created when nuclear fuel undergoes nuclear fission. Most nuclear fuels contain heavy fissile actinide elements that are capable of undergoing ...

. The coating is usually deposited by thermal

chemical vapor deposition Chemical vapor deposition (CVD) is a vacuum deposition method used to produce high quality, and high-performance, solid materials. The process is often used in the semiconductor industry to produce thin films. In typical CVD, the wafer (substra ...

in a

fluidized bed reactor A fluidized bed reactor (FBR) is a type of reactor device that can be used to carry out a variety of multiphase chemical reactions. In this type of reactor, a fluid (gas or liquid) is passed through a solid granular material (usually a catalyst) ...

. It also has high emissivity and high current capacity at elevated temperatures rendering it as a promising material for use in thermo-photovoltaic radiators and field emitter tips and arrays. It is also used as an

abrasive An abrasive is a material, often a mineral, that is used to shape or finish a workpiece through rubbing which leads to part of the workpiece being worn away by friction. While finishing a material often means polishing it to gain a smooth, reflec ...

, in

cladding Cladding is an outer layer of material covering another. It may refer to the following: *Cladding (boiler), the layer of insulation and outer wrapping around a boiler shell *Cladding (construction), materials applied to the exterior of buildings ...

, in

s, incandescent filaments and cutting tools.

Production

Zirconium carbide can be fabricated in several ways. One method is carbothermic reaction of zirconia by graphite. This results in a powder. Densified ZrC can then be made by sintering the powder of ZrC at upwards of 2000 °C. Hot pressing of ZrC can bring down the sintering temperature and consequently helps in producing fine grained fully densified ZrC. Spark plasma sintering also has been used to produce fully densified ZrC. Zirconium carbide can also be fabricated by solution based processing. This is achieved by refluxing a metal oxide with acetylacetone. Another method of fabrication is chemical vapour deposition. This is achieved by heating a zirconium sponge and parsing halide gas through it. Poor oxidation resistance over 800 °C limits the applications of ZrC. One way to improve the oxidation resistance of ZrC is to make composites. Important composites proposed are ZrC-ZrB₂ and ZrC-ZrB₂-SiC composite. These composites can work up to 1800 °C. Another method to improve this is to use another material as a barrier layer such as in TRISO fuel particles.

References

{{Zirconium compounds Zirconium(IV) compounds Carbides Superhard materials Refractory materials Rock salt crystal structure