1. Introduction
Transition metals and their alloys, compounds, and large complexes containing transition metals are widely used for a variety of purposes ranging from specialized high-temperature applications to more common uses, such as in catalysis, materials synthesis, photochemistry, biological systems, environment cleaning, and electronics. The fabrication of transition-metal-based functional oxides and hydroxides from aqueous metal-oxo cluster precursors and electrochemical routes has opened up numerous opportunities for the development of sustainable green chemistry. These suitable chemistries have led to the development of new materials for energy generation and storage, data storage, and many other potential applications. Although metal-oxo cluster chemistries, pertaining to group V and VI elements, have been widely reported, some of the issues pertaining to ligand dynamics, post-synthesis ligand exchange, and cluster stability have largely remained unresolved [
1]. While the controlled electrochemical synthesis approach has limited benefits, researchers have been unable to resolve some of the difficulties related to synthesis because of the prevalence of incomplete solid-state diffusion kinetics [
2]. Like the transition metal-oxo clusters, researchers have also developed rare-earth metal hexacyanoferrates for electrocatalysis and adsorbents for heavy ion removal applications [
2,
3,
4,
5,
6,
7]. In addition to the transition and rare-earth metal complexes, hexacyanoferrate simple oxides are also widely used in many technologies.
Many sectors use two of the group V oxides, Ta
2O
5 and Nb
2O
5. Because of its excellent dielectric properties, Ta
2O
5 is used in dynamic random access memory chips, field effect transistors, thin-film electroluminescence devices, biological and chemical sensors, antireflection coatings for silicon solar cells, charge-coupled devices, corrosion-resistant materials, optical wave guides, and thin-film resistors [
8]. Nb
2O
5, on the other hand, exhibits strong redox abilities and unique Lewis and Brønsted acid sites, and as a result has been used for photocatalytic activities [
9]. Another application of Nb
2O
5 has been in the fabrication of resistive random memory access devices because of the dependence of its dual electrical response of memory and threshold switching behaviors on oxygen contents resistive to random memory access devices [
10]. Nb
2O
5 is routinely used in gas sensors, catalysis, optical and electrochromic devices, solid-state electrochemical devices, and biocompatible prostheses [
11]. Because of the similarity in their chemical and structural properties, Ta
2O
5 and Nb
2O
5 mixed oxides have been used as coatings and thin films to either enhance the dielectric permittivity of Ta
2O
5 or the band gap of Nb
2O
5 [
12]. Forming a mixed oxide phase, a solid solution of Nb
2O
5 and Ta
2O
5 (NbTaO
5, (Ta
1−xNb
x)
2O
5(Ta
1−xNb
x)
2O
5, x = 0.02–0.07) is advantageous in terms of having a lower leakage current and enhanced dielectric permittivity in the device [
12,
13]. Fine (micron-sized) Nb
2O
5 and Ta
2O
5 powders formed reactive thermites and composites with nanosized aluminum, where the oxide mixture acted as the gasless oxidizer and the metal (aluminum) was a fuel [
14].
Binary alloys of niobium and tantalum can serve as anticorrosion coatings (for CoCr alloys in the biomedical industry) [
15] in the fabrication of high-entropy shape memory and superconducting alloys [
16,
17,
18]. These applications employ a melting-cum-remelting process to make a homogeneous alloy from which the components are fabricated. In recent years, researchers have developed a novel electrochemical process to fabricate many metallic materials, both metals and alloys, from their oxide and mixed oxide intermediates. Although both Ta
2O
5 and Nb
2O
5, individually, have been successfully converted to tantalum and niobium, respectively, in molten salts [
19,
20,
21], studies on the co-reduction of the mixed oxides in molten salts to form the binary (NbTa) alloy are absent in the literature. Both Nb
2O
5 and Ta
2O
5 were mixed with other oxides (TiO
2, ZrO
2, and HfO
2) to form high-entropy alloys, consisting of titanium–niobium–tantalum–zirconium and titanium–niobium–tantalum–zirconium–hafnium, in a calcium chloride melt [
22]. However, no studies appear to have reported on the formation of the binary alloys from their mixed oxide precursors. Three types of salts (LiCl-Li
2O, CaCl
2-CaO, and eutectic CaCl
2-NaCl) have been used to electrochemically reduce metal oxides to their metallic constituent. Each electrolyte system offers a set of advantages and disadvantages. CaCl
2 provides two distinct advantages: the relatively higher solubility of the oxide ions in calcium chloride and enhanced reduction kinetics, thereby decreasing the overall reduction time. The objective of the present study was to examine the co-reduction behavior of the mixed oxides in a calcium chloride melt. The experimental research was divided into two parts: (1) the preparation, evaluation, and characterization of mixed oxide precursor; (2) the electrochemical reduction of precursor materials prepared under a set of optimum conditions. The present manuscript describes the experimental results pertaining to the preparation and characterization of mixed oxide precursors. The experimental work consisted of the mixing and homogenization of Ta
2O
5 and Nb
2O
5, thermal analyses of the powder, the pelletization of the homogenized powder, the sintering of the mixed powder, a study of the powder’s morphology using a scanning electron microscope, and phase analyses of the heat-treated powders via room- and high-temperature X-ray diffraction.
2. Materials and Methods
2.1. Materials
High-purity and finely powdered tantalum pentoxide (Ta2O5, Sigma-Aldrich (St. Louis, MO, USA) 99.99% trace metals basis, <20 µm) and niobium pentoxide (Nb2O5, Sigma-Aldrich, 99.9% trace metals basis, −325 mesh) were used as the starting materials. Polyvinyl alcohol/[poly (vinyl butyral-co-vinyl alcohol-co-vinyl acetate)] (PVB/PVA), Sigma-Aldrich, average MW = 50,000–80,000 by gel permeation chromatography (GPC) and poly (ethylene glycol, PEG, Sigma-Aldrich, average MW = 200) were used as the binder to prepare the powder mixture. Finally, the powder mixture was homogenized in a ball miller for 4 h and the slurry was dried (under a heat lamp) over a period of ~36 h.
2.2. Equipment
A thermogravimetric analyzer (simultaneous TGA–DSC, SDT Q600, TA instruments, New Castle, DE, USA) performed the initial heat treatment of the milled (mixed) oxide powder. An MTI 1100X Series tube furnace (MTI corporation, Richmond, CA, USA) sintered the pelletized powder mixture. An X-ray diffraction unit with PDXL (Rigaku, Japan) and JADE software (MDI, Hibbing, MN, USA) programs analyzed the diffraction patterns. A small furnace containing a platinum tray and a scintillation detector was used to collect X-ray diffraction (XRD, Rigaku Ultima IV diffractometer) data. A D/teX Ultra detector (Rigaku, Tokyo, Japan) recorded the room-temperature XRD patterns of the sintered pellets. A scanning electron microscope (MIRA3 TESCAN SEM, TESCAN USA, Inc., Warrendale, PA, USA) with an energy-dispersive X-ray (EDS) analysis attachment was used to examine the sintered pellet morphologies.
2.3. Procedure
Calculated quantities of Ta
2O
5 and Nb
2O
5 powders were mixed and homogenized in an agate mortar and pestle. About 8–15 mg powders were placed in an alumina crucible, which in turn was loaded into the simultaneous TGA–DSC unit. The mixed powder was heated at 5 °C/min to a maximum temperature of 1150 °C to record the endo- and exothermic peaks. This heating was performed under a continuous argon flow. Depending on the thermogram results, a few powder compositions were formulated to record the exothermic and endothermic peaks and percentage mass loss. A laboratory hydraulic pressing unit was used to pelletize the milled powder. The powder was compacted into 13 mm dia. pellets in a steel die by applying around 29–29.6 MPa of pressure. The green pellets were subsequently loaded into an alumina boat and heated in air/hydrogen up to the desired temperatures (up to 950 °C) for fixed durations (1–4 h). The sintered pellets were subsequently evaluated with respect to their phase compositions and morphological features with a 10 °C/min heating rate to record the in situ high-temperature XRD data. The temperature controller was set up to hold at the set temperature for 5 min in order to have a sample with a uniform temperature across its surface. The detailed information pertaining to the preparation of samples and experimental procedure is described elsewhere [
23].