Solid-state reaction between BaCO
3 and ZrO
2 is the simplest method to prepare BaZrO
3, which is an important refractory structural material with a very high melting point and a low chemical reactivity. However, since the solid-state formation of the BaZrO
3 phase requires high calcination temperature, this method typically produces larger particles unsuitable for the sintering process than the solution methods. In this study, we investigated the reaction behavior between very fine ZrO
2 (70 nm) and coarse BaCO
3 (1.5–5.7 µm) and described the water vapor-assisted solid-state synthesis of BaZrO
3. Nanocrystalline BaZrO
3 powder (~80 nm) was obtained by solid-state reaction at 1050°C in air. The BaZrO
3 formation was accelerated by water vapor-assisted reaction. The apparent activation energy for the formation reaction was calculated to be 323 ± 21 kJ/mol and 263 ± 46 kJ/mol in air and humid air with H
2O of 0.5 atm, respectively. In the 1 atm water vapor atmosphere, almost single-phase BaZrO
3 was obtained by calcination at 750°C.
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