Preparation of spherical Gd2Zr2O7 powders by RF induction thermal plasma process

Spherical Gd2Zr2O7 (GZO) powders with a uniform particle size distribution are successfully prepared using a novel industrial approach, which combines spray-drying process and thermal plasma sintering technology together. In this, GZO powders with pyrochlore structure as the main phase are first synthesized via a solid-state reactive route using a mixture of the milled Gd2O3 powders and ZrO2 powders as starting materials. The influence of sintering temperature on the microstructure of prepared powders is researched. Then, GZO granules are prepared after wet-grinding and spray-drying process, which exhibit a spherical shape with the average particle size of 46.5 mu m. RF induction thermal plasma is finally used to sinter the granulated particles, and the influence of feeding rate on the properties of spherical powders is investigated. The apparent density of plasma sintered GZO spherical powders is increased from 1.53 g/cm3 to 2.29 g/cm3 when the feeding rate of granulated powders is 80 g/min, and further increased up to 3.90 g/cm3 when the feeding rate is 15 g/min. Such powders are in potential demand for plasma sprayed coatings and additive manufacturing techniques, and the successful synthesis of spherical GZO powders may guide the way toward the preparation of many other spherical rare earth zirconates powders.