Fabricating nanoscale metal carbides
is a great challenge
due to
them having higher Gibbs free energy of formation (ΔG°) values than other metal compounds; additionally,
these carbides have harsh calcination conditions, in which metal oxidation
is preferred in the atmosphere. Herein, we report oxocarbon-mediated
calcination for the predictive synthesis of nanoscale metal carbides.
The thermochemical oxocarbon equilibrium of CO–CO2 reactions was utilized to control the selective redox reactions
in multiatomic systems of Mo–C–O, contributing to the
phase-forming and structuring of Mo compounds. By harnessing the thermodynamically
predicted processing window, we controlled a wide range of Mo phases
(MoO2, α-MoC1–x
, and β-Mo2C) and nanostructures (nanoparticle,
spike, stain, and core/shell) in the Mo compounds/C nanofibers. By
inducing simultaneous reactions of C–O (selective C combustion)
and Mo–C (Mo carbide formation) in the nanofibers, Mo diffusion
was controlled in C nanofibers, acting as a template for the nucleation
and growth of Mo carbides and resulting in precise control of the
phases and structures of Mo compounds. The formation mechanism of
nanostructured Mo carbides was elucidated according to the CO fractions
of CO–CO2 calcination. Moreover, tungsten (W) and
niobium (Nb) carbides/C nanofibers have been successfully synthesized
by CO–CO2 calcination. We constructed the thermodynamic
map for the predictive synthesis of transition metal carbides to provide
universal guideline via thermochemical oxocarbon equilibrium. We revealed
that our thermochemical oxocarbon-mediated gas–solid reaction
enabled the structure and phase control of nanoscale transition metal
compounds to optimize the material–property relationship accordingly.