Synthesis of nonstoichiometric zirconium carbide whiskers by chemical vapor deposition

Nonstoichiometric zirconium carbide crystals with various compositions were prepared by chemical vapor deposition. Two gaseous mixtures, zirconium tetrachloride and argon, toluene and hydrogen, were introduced to the reaction zone where a graphite substrate was heated between 1200 and 1400°C. The deposition rate was proportional to the partial pressure of toluene. The compositional ratio of n_C/n_Zr in the gaseous mixture from 2.0 to 6.0 was found to be optimum for producing needle-like crystals. Needle-like crystal with smaller size were formed when the ratio of n_C/n_Zr was smaller than 2.0, and less needle-like crystals accompanied with more carbon were also produced when the ratio of n_C/n_Zr was larger than 6.0. The temperature of the substrate suitable for the growth of needle crystals was in the range from 1250 to 1300°C. The lattice constants of the products varied as a function of the ratio of n_C/n_Zr in the gaseous mixtures.