Microstructure and reduction behavior of Mo powders doped with La2O3 and ZrO2 oxides using the spray drying method

In the present contribution, we used the spray drying method for the preparation of molybdenum-based composite powders, which belong to an important class of high-temperature structural materials – oxide dispersion strengthened molybdenum alloys (ODS-Mo). Three types of materials were prepared via spray drying and subsequent steps of calcination and reduction, including undoped reference Mo, ODS-Mo doped with 1 wt% of La2O3, and ODS-Mo doped with 1 wt% of La2O3 and 1 wt% of ZrO2. The particular focus was given to precursor solution; specifically, the effects of type (aqueous or water-ethanol mixture) and chemical composition (the addition of La and Zr precursors) were studied in detail, which was rarely given attention in previous research. The morphological and microstructural changes of the particles during oxidation and reduction of sprayed-dried powders were extensively analysed by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDX), X-ray diffractometry (XRD), and X-ray photoelectron spectroscopy (XPS). The morphology and crystallinity of spray dried powders were controlled by the state of spraying precursor solution, i.e. homogeneous solution or particle suspension. Calcination at the temperatures of 500 °C and 650 °C produced spherical polycrystalline and slab-shaped monocrystalline MoO3 oxide particles. Subsequent reductive treatment of transformed calcined powders into metal-based powders took place with efficiency that depended mainly on the type of spraying solution (aqueous solution or water-ethanol suspension) and its chemical composition, in which case, the addition of La and Zr precursors resulted in lower efficiency than the addition of La alone. In terms of powder particle size, homogeneity of alloying elements, and reduction efficiency, the powders produced from water-ethanol suspensions were clearly superior to those produced from aqueous solutions. •La and La-Zr doped Mo powders were produced by spray drying/calcination/reduction.•Spraying solution (aqueous vs. water-ethanol) affected microstructure of powder.•Calcination at 500/650 °C produced spherical/slab-shaped particle morphology.•Undoped and La-doped powders reduced more efficiently than La-Zr doped powder.•Powders dried from water-ethanol and calcined at 500 °C have optimal properties.