Exploration of a Novel Low Temperature Metallization Process

Sustainability efforts and supply chain anxieties are driving increased interest in low temperature metallization processes as they are often energy and cost intensive. The objective of this study is to test and refine a novel room-temperature metal reduction procedure. The process uses a low-cost, abundant metal as a reducing agent, enabling all metal chlorides to be converted to the corresponding metals. Experiments have shown that copper and iron metal can be reduced at room temperature in under an hour, significantly shorter than competing processes. X-ray diffraction patterns on the powders obtained across different trials showed consistently amorphous content alongside byproduct peaks . Further characterization, including X-ray photoelectron spectroscopy and scanning electron microscopy, indicates nanophase metals may be forming. The current success with iron and copper shows the potential and validity of this reduction pathway. Future work will examine other metals conventionally produced by high-temperature processes at 800-2000ÀöC, such as Mg, Ti, Ca, and rare-earth elements.