Zirconium Diboride (ZrB2) powder was synthesized at low temperature via a Direct Molten Salt Reaction (DMSR) method. The influence of different salt compositions including eutectic mixture of (KF-NaF), (KF-KCl) and (KCl-NaCl) on the morphology and purity of the products were studied. The obtained samples were characterized by scanning electron microscopy (SEM) and X-ray diffraction (XRD). Alongside eutectic mixture of chloride salt, ZrB2 powder can obtained with eutectic mixture of fluoride salt. The results showed that ZrB2 powder obtained with no additional salt has hexagonal prism morphology whereas ZrB2 particles prepared with eutectic mixture of fluoride salt have higher purity and particle size and hexagonal morphology as well. ZrB2 Powder obtained in chlorofluoride salt has lower particle size and purity and no uniform morphology. Prepared ZrB2 powder is different from starting material in term of morphology and particle size therefore the dissolution–precipitation mechanism may play a dominant role in the current molten salt synthesis of ZrB2.
