Preparation of BaZrO₃ powders by a spray-drying process

The potential use of barium zirconate for the manufacture of corrosion-resistant substrates emphasizes the need for a simple, inexpensive, and easily scalable process to produce high-quality powders with well-controlled composition and properties. However, the classical solid-state preparation of barium zirconate leads to an inhomogeneous powder unsuitable for applications in highly corrosive environment. For this paper, the possibility to use the spray-drying technique for the preparation of BaZrO₃ powders with a controlled size distribution and morphology was investigated. The influence of the nature and concentration of the precursor solution and the influence of the spray-drying step are discussed on the basis of x-ray diffraction, Fourier transform infrared spectroscopy, scanning electron microscopy, and dilatometric measurements.