Microwave processing for carbide ceramics

The US Bureau of Mines (USBM) has developed a process for synthesizing carbide ceramics in a microwave-induced plasma (MIP). For example, the process forms tungsten carbide with only 0.04% free carbon impurity at an average particle size of 0.05 {mu}m. Starting materials are tungsten oxide, carbon, and carbon monoxide. Commercial methods to produce tungsten carbide require heating to 1,500 C for up to 7 hours. Using the USBM method, tungsten carbide can be produced in approximately 10 minutes using a 30 kW, 915 mHz microwave unit. The reaction is carried out in a short-circuited waveguide to create a standing wave. Reactants rest on a carbon pedestal inside a closed zirconia crucible filled with carbon monoxide. The crucible is place at a field maximum within the waveguide. The waveguide was filled with helium to protect the waveguide. A procedure for producing carbide on a larger scale is described. Other ceramic compounds have been produced using this method, including silicon carbide and titanium carbide.