Solid Oxide Membrane (SOM) Process for Facile Electrosynthesis of Metal Carbides and Composites
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INTRODUCTION
METAL carbides (MCs) and composites have attracted significant attention because their widespread usage in industry.[1–7] In particular, transition metal carbides (TMCs) are of interest due to their superior properties such as high melting points, excellent electronic characteristics, and good catalytic behaviors, etc.[5–7] TaC is an especially interesting compound among the TMCs, as it has some remarkable properties such as high melting point [above 4153 K (3880 C)] and high hardness.[8,9] SiC is a wide bandgap refractory carbide used in high power electronics and catalyst supports, etc.[10] TiC and ZrC show interesting physical and mechanical properties which are suitable for XINGLI ZOU, Associate Professor, SHANGSHU LI, Ph.D. Candidate, and XIONGGANG LU, QIAN XU, and WEIZHONG DING, Professors, are with the State Key Laboratory of Advanced Special Steel & Shanghai Key Laboratory of Advanced Ferrometallurgy & School of Materials Science and Engineering, Shanghai University, Shanghai 200072, P.R. China. Contact e-mails: xinglizou@ shu.edu.cn; [email protected] CHAOYI CHEN, Associate Professor, is with the School of Materials and Metallurgy, Guizhou University, Guiyang 550025, P.R. China. ZHONGFU ZHOU, Professor, is with the State Key Laboratory of Advanced Special Steel & Shanghai Key Laboratory of Advanced Ferrometallurgy & School of Materials Science and Engineering, Shanghai University, and also Lecturer with Institute of Mathematics and Physics, Aberystwyth University, Aberystwyth SY23 3BZ, U.K. Manuscript submitted June 21, 2016. METALLURGICAL AND MATERIALS TRANSACTIONS B
applications as structural components in the nuclear industry.[11] NbC is a promising material used for cutting tools, microelectronic devices, and catalyst.[12,13] In addition, carbide-containing composites such as Ti5Si3/TiC have also received considerable research interest because of their unique physical and chemical properties.[14–18] In the past decade, much effort has been devoted to the synthesis of MCs and composites. However, MCs and composites are still commonly fabricated by powder metallurgical techniques at elevated temperatures, such as the carbonization of metal elements at high temperatures [>1773 K (1500 C)].[1] For example, NbC and TaC carbides are usually synthesized from their metal oxides (MOs) precursors mixed with carbon powder at temperature over 1773 K (1500 C).[3] These methods are typically high-energy cost processes, and the products are generally composed of large particles.[3] However, these large particles commonly only have poor performance in many applications such as the catalytic application due to their low surface areas. In contrast, MCs and composites with small particles generally exhibit excellent performance in many applications.[2,10,13,19] Therefore, searching for new route for the facile production of micro/nanostructured MCs and composites is extremely needed. Recently, the solid-to-solid electroreduction method[20] has been successfully used to extract metals/alloys from their c
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