Methods of making titanium diboride powders

Abstract

The present disclosure is directed towards methods of making titanium diboride products in various sizes. An aspect of the method provides (a) selecting a target average particle size for a target titanium diboride product; (b) selecting at least one processing variable from the group consisting of: an amount of sulfur, an inert gas flow rate, a soak time, and a reaction temperature; (c) selecting a condition of the processing variable based upon the target average particle size; and (d) producing an actual titanium diboride product having an actual average particle size using the at least one processing variable, wherein due to the at least one processing variable, the actual average particle size corresponds to the target average particle size.

1 - 18 . (canceled) 
     
     
         19 . A reactor for carbothermically producing titanium diboride, comprising:
 a vessel having a perforated separator therein, wherein the perforated separator is configured to allow fluid communication between the upper chamber and the lower chamber;   a lower chamber defined by the vessel and the perforated separator, the lower chamber further comprising an inert gas inlet, wherein the lower chamber comprises a non-reactive media retained therein and configured to heat an inert gas as it enters the inlet and passes through the lower chamber to the perforated separator,   an upper chamber defined by the vessel and the separator plate, wherein the upper chamber is configured to house a precursor mixture, wherein the upper chamber comprises an inert gas vent configured to direct inert gas out of the upper chamber;   wherein, via the perforated separator, a heated inert gas passes from the lower chamber to the upper chamber to react the precursor mixture to form a titanium diboride product.   
     
     
         20 . The apparatus of  claim 19 , wherein the upper chamber comprises an agglomerated precursor mixture. 
     
     
         21 . The reactor of  claim 19 , wherein the non-reactive media comprises alumina balls. 
     
     
         22 . The reactor of  claim 19 , wherein the reactor temperature is at least about 1500° C. 
     
     
         23 . The apparatus of  claim 19 , wherein the precursor mixture comprises:
 a boron source; a carbon source; and a titanium source.   
     
     
         24 . The apparatus of  claim 19 , wherein the vessel comprises a graphite reactor vessel. 
     
     
         25 . The apparatus of  claim 19 , further comprising a furnace configured to heat the reactor. 
     
     
         26 . The apparatus of  claim 19 , further comprising at least one thermocouple configured to monitor the reaction within the upper chamber.