Zirconium diboride is a strategic material, finding applications as thermal protection system in reentry vehicles, high temperature electrode, thermowell tubes, etc. Solid state reactions require high temperature and thus result in coarse powders which are difficult to sinter. Densification of ZrB2 is extremely difficult due to its refractory nature. Sinter additives help in densification but deteriorate the high temperature properties. In the recent past, various researchers have made attempts to improve the existing methods and also invented new processes for synthesis of pure and fine powders as well as for densification of ZrB2. All the techniques on synthesis and consolidation of ZrB2 are discussed in detail and critically reviewed in this article.
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