Low temperature synthesis of CaZrO3 nanoceramics from CaCl2–NaCl molten eutectic salt

CaZrO3 nanoceramics were successfully synthesized at 700 C using the molten salt method, and the effects of processing parameters, such as temperature, holding time, and amount of salt on the crystallization of CaZrO3 were investigated. CaCl2, Na2CO3, and nano-ZrO2 were used as starting materials. On heating, CaCl2–NaCl molten eutectic salt provided a liquid medium for the reaction of CaCO3 and ZrO2 to form CaZrO3. The results demonstrated that CaZrO3 started to form at about 600C and that, after the temperature was increased to 1,000C, the amounts of CaZrO3 in the resultant powders increased with a concomitant decrease in CaCO3and ZrO2 contents. After washing with hot distilled water, the samples heated for 3 h at 700C were single-phase CaZrO3 with 90–95 nm particle size. Furthermore, the synthesized CaZrO3 particles retained the size and morphology of the ZrO2 powders which indicated that a template mechanism dominated the formation of CaZrO3 by molten-salt method.