ZrB2 is of particular interest among ultra-high temperature ceramics because it exhibits excellent thermal resistance at high temperature, as well as chemical stability, high hardness, low cost, and good electrical and thermal conductivity, which meet the requirements of high-temperature components of hyper-sonic aircraft in extreme environments. As raw materials and basic units of ultra-high temperature ceramics and their composites, ZrB2 powders provide an important way for researchers to improve material properties and explore new properties by way of synthesis design and innovation. In recent years, the development of ZrB2 powders' synthesis method has broken through the classification of traditional solid-phase method, liquid-phase method, and gas-phase method, and there is a trend of integration of them. The present review covers the most important methods used in ZrB2 nanopowder synthesis, focusing on the solid-phase synthesis and its improved process, including modified self-propagating high-temperature synthesis, solution-derived precursor method, and plasma-enhanced exothermic reaction. Specific examples and strategies in synthesis of ZrB2 nano powders are introduced, followed by challenges and the perspectives on future directions. The integration of various synthesis methods, the combination of different material components, and the connection between synthesis and its subsequent application process is the trend of development in the future.
Keywords: ZrB2 nanopowders; plasma technology; self-propagating high-temperature synthesis; solid-state synthesis; solution-derived precursors; ultra-high temperature ceramics.