Size-controlled preparations of tungsten and molybdenum borides in calcium or aluminum melt

Tungsten and molybdenum borides are widely used in ultra-high temperature ceramics (UHTCs) and electrode material. In this research, ultra-fine and ultra-coarse binary borides (WB, W 2 B 5 , MoB, Mo 2 B 5 ) and MoAlB powders were prepared with W/Mo and B 4 C as raw materials and Ca/Al as the decarbonization agent. The feasibility of using Ca and Al as decarburizing agents was assessed by thermodynamic calculations. Meanwhile, the effects of reaction temperature, decarbonization agent type and its additional amount on the phase, morphology and size distribution of the powder products were thoroughly investigated. The results revealed that single phase products with carbon content of less than 1 wt% could be prepared. Moreover, the morphology and particle size of products were significantly affected by the reaction temperature and type of decarburization agent. When using Ca as the decarburizing agent, ultra-fine WB and MoB powders were effectively prepared, probably owing to the fact that W/Mo are essentially insoluble in Ca melt. However, the great solubility of W/Mo in Al makes it easily to synthesize ultra-coarse borides at high temperatures via the dissolution-precipitation mechanism. Additionally, ultra-fine borides particle can also be prepared by lowering the temperature and amount of Al to weak the dissolution-precipitation mechanism.