Synthesis of MoS2 Nanopowder Based on the Design of the Experiment with Taguchi

Document Type : Research Paper

Authors

1 Department of Chemistry, Sayyed Jamaleddin Asadabadi University, Asadabad 6541853096, Iran

2 Department of Materials Engineering, Faculty of Mechanical Engineering, University of Tabriz, Tabriz, Iran

3 Department of Chemistry, Tuyserkan Branch, Islamic Azad University, Tuyserkan, Iran

10.22052/JNS.2026.01.075

Abstract

Molybdenum disulfide nanopowders (MoS2) have been successfully prepared via solvothermal method using different precursors of molybdenum and sulfur, at different times and temperatures. According to L9 Taguchi orthogonal design, synthesizing process parameters of MoS2 powder are optimized for producing smaller powders with four process parameters, viz., and precursor of molybdenum, the precursor of sulfur, different times, and reaction temperatures. The prepared MoS2 powders were examined via scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS), Fourier transform infrared spectrometer (FTIR), X-ray diffraction (XRD), and differential thermal analysis (DTA). SEM measurements were conducted to determine the grain size of the powders. According to the study conducted by Taguchi, the Mo precursor and reaction temperature had the most substantial effect on the particle size of MoS2. Finally, optimum conditions were achieved as follows: molybdic oxide as Mo precursor, sodium sulfide as a sulfur source, 72 h, and 150 °C as reaction time and temperature. The hexagonal 2H-MoS2 can be easily indexed for the XRD pattern of the sample synthesized from optimum conditions. FTIR spectrum of the optimized MoS2 showed the band at 469 cm-1 corresponds to the ν (Mo-S) and its SEM image exhibited the MoS2 nanolamellar with a diameter of 40-90 nm.

Keywords


INTRODUCTION
Transition metal dichalcogenides MX2 (M = Mo, W, Nb and Ta, X = S, Se), in which a layered structure is constituted in comparison to graphite, has recently generated considerable interest. The reason for this increasing popularity is their promising applications and prominent characteristics [1, 2]. Nanoparticles of many inorganic compounds, including MoS2, WS2 have not enough stability against folded in comparison to graphite, and are capable of adopting fullerene-like and nanotubular structures [3]. Their synthesis has recently received increasing attention since they can be potentially employed in the realm of catalysis [4, 5], lubrication [6-8], electrochemistry [9, 10], and as host materials in intercalation chemistry [11, 12]. Since the characteristics of materials are affected by its shape and size, for example, nanoscale MoS2 has more favorable characteristics in comparison to normal MoS2, including much greater particular surface areas, considerable absorbing ability, particularly hydro-desulfurization (HDS) catalyzing capability [13, 14]. Thus, more attempts have been made in the synthesis of several MoS2 nanoscales having distinctive characteristics and particular morphologies. There have been various MoS2 structures, such as inorganic fullerene [15, 16], micro and nano flowers [17, 18], nanotubes [19-21], nanorods [22, 23], nanowires [24, 25], nanolamellar [26] and core-shell structures [27, 28].
There have been several preparation approaches for various nanostructural materials, including chemical vapor deposition, spray pyrolysis, sol-gel processing, metathesis reactions, two-step electrochemical synthesis, co-precipitation, sonochemical synthesis, and so on [29-32]. The first discovery of spherical fullerene-like nanoparticles of MoS2 and WS2 nanotubes was made by Tenne et al. in 1992 [33]. MoS2 nanotubes were achieved by Rao et al. via simple heating MoS3 under high temperature in a stream of hydrogen. An attempt was made by Zelenski et al. to synthesize tubules and fibers of MoS2 using the thermal decomposition of ammonium thiomolybdate precursors at 450 °C [34]. The hydrothermal approach was utilized by Yumei et al. to synthesize MoS2 nanospheres and nanorods [23, 35]. As water is applied as a reaction solvent instead of organics, hydrothermal synthesis as an environmentally friendly method has received great attention. As this approach is a simple, low-cost, and high-efficiency approach, it has been extensively applied for the preparation of nanostructures [36].
In this study, the Taguchi approach is applied reports to specify the optimum synthesizing process factors to achieve molybdenum disulfide powder with nano metric scale. According to the Taguchi orthogonal, four design factors of precursor of molybdenum, precursor of sulfur, duration, and the temperature of reaction are involved in the experiments on the morphology of the MoS2. Three levels of maximum, minimum, and middle levels are considered for the selected parameters.

 

MATERIALS AND METHODS
Materials
The applied chemicals and materials used during the tests were listed in the following: sodium molybdate dihydrate (Na2MoO4·2H2O, 99%, Merck), ammonium heptamolybdate tetrahydrate (NH4)6Mo7O24·4H2O, 99%, Merck), molybdic oxide (MoO3, 99%, Merck), potassium thiocyanate (KSCN, 99%, Merck), thioacetamide (C2H5NS, 99%, Aldrich), sodium sulfide (Na2S, 99%, Merck), doubly distilled water was used for the preparation of the solutions.

 

Synthesis and characterization of MoS2 powders 
The synthesis of MoS2 nanopowders was classified divided into two phases. A typical procedure was as follows. In the first trail, Mo source (Na2MoO4·2H2O, (NH4)6Mo7O24·4H2Oor MoO3) were put into a Teflon-lined autoclave with a capacity of 100 ml. The autoclave was then filled with 20 ml distilled water and 40 ml ethanol. A stainless steel tank was used to seal the autoclave, and it was equilibrated at 50 °C for 4 h. Secondly, the sulfur precursor (KSCN, Na2S, or C2H5NS) was put into the autoclave, and 5 mL distilled water and 10 mL ethanol was added to it. The mole ratio of Mo precursors to the sulfur source is 1:2. The autoclave was kept at 150, 200, and 250 °C respectively for 24 h, 48 h, and 72 h, and the temperature was naturally reduced to room temperature.
Centrifugation method was conducted to retrieve the powder from the solution, and it was washed by ethanol and distilled water for several times to eliminate the reactants residue, and finally dried in air.
A field emission scanning electron microscope (FESEM) model TESCAN MIRA3 electron microscopy was employed for determining the particle morphology and the powders size. Furthermore, energy dispersive X-ray spectroscopy (EDS) experiments carried out in the SEM were also used to specify the composition of the synthesized powders.
After drying, the synthesized powders were analyzed by XRD (X-Ray Diffractometer APD 2000, Cu-kα radiation) and thermo gravimetric analysis and differential thermal analysis (TG/DTA) (Pyris diamond TG/DTA, Perkin Elmer). TG/DTA of powders was performed from 30 to 1100 °C at a scan rate of 10 °C /min under inert nitrogen atmosphere. The Fourier transform infrared spectrum of the samples (FTIR) was collected by PerkinElmer Spectrum Two FT-IR spectrometer.

 

TAGUCHI DESIGN OF EXPERIMENT 
Design of orthogonal array and signal-to-noise analysis
Taguchi method [37, 38] is accounted for as an effective technique to design the high-quality systems according to orthogonal array trials in which much-reduced variance for the trials and an optimum setting of the procedure control factors are provided. In this approach, the design of experiments (DOE) is integrated with the parametric optimization of the procedure by which favorable results are obtained [37, 38]. Four factors (type of molybdenum precursor, type of sulfur precursor, time, and reaction temperature) selected with three levels are demonstrated in Table 1. 
The levels and parameterswere appliedtodesignan orthogonal array L9 (34) for the trials. To make sure the reliability of experimental data is achieved for a signal-to-noise (S/N) analysis,the nine Taguchi experiments were carried outtwice. Various repetitions are integrated into one value bt the S/N ratio to reflect the amount of variation present which is described as the ratio of the average(signal) to the standard deviation (noise). There have been three types of S/N ratios [38]: lower is best (LB), higher is best (HB) and nominal is best (NB). In this survey, particle size is consideredas a characteristic value. The parameters optimization was conducted with an objective for minimizing the particle size. Hence, the S/N ratio for LB characteristics was adopted and measured in the following:



Where n and Qi are the repetition number of each trial for design factors under the same condition and the particle size of an individual evaluation at the i th experiment. The optimal level, considered as the maximum S/N ratio compared to all the parameters levels, was measured after the average S/N ratios specified and plotted at each level for different parameters.
Analysis of variance (ANOVA)
ANOVA is a statistical approach by which some major conclusions can be inferred according to the analysis of the experimental data. Identifying the significance level of factor(s) influence and the contribution of factors to the particle size of powders can be relatively simple after the analysis. The total variability of the response is divided into contributions of each of the parameters and the error [39-41]. According to the ANOVA table, SS, D, V, SS′, and P is the sum of the square, the degree of freedom, the variance, the corrected sum of the square, and the percentage contribution of each parameter, respectively [38].
 
RESULTS AND DISCUSSION
Particle size studies
To calculate the grain size of the powders, SEM measurements were performed. Table 2 presents the structure of the Taguchi’s orthogonal array design as well as the grain size measurements results for various powders. The particle size of powders produced from different experiments is in the range of 50-950 nm.

 

Determination of optimal levels
According to Eq. 1, two grain size measurements were converted into an S/N ratio for each experiment. A comparison made between the calculated mean S/N ratios and the data of particle size is tabulated in Table 3. 
According to Table 4 which is named the S/N response table for grain size, the average S/N ratio for each level of the parameters A, B, C, and D is shown. Furthermore, it shows the total average S/N ratio for the 9 trials. 
The mean value of the adopted properties for the level of each parameter is tabulated in the response Table 4. This table also shows ranks according to Delta statistics in which a comparison between the relative magnitudes of effects is made. The maximum average value of each factor minus the minimum average value of the same is defined as the Delta statistic. Ranks are considered according to Delta values; rank 1 is related to the maximum Delta value, rank 2 to the second-highest Delta value, and so on. Figs 1 and 2, demonstrate the plots of the main effect and interaction effect between the parameters. According to the plot in Fig. 1, a particular factor has no substantial effect if the line for the factor is near horizontal [37-40]. Therefore, it can be seen that parameters D (reaction temperature) and A (Mo source type) have the most substantial effect while parameters B (S source type) and C (reaction time) have relatively less significant influence (Fig. 1). 
On the other hand, according to the plot Fig. 2, interaction occurs if the lines are non-parallel, and strong interaction occurs between factors if the lines cross [37-40]. Therefore, it is obvious that there is a strong interaction between the factors A and B, whereas there is a moderate interaction between the factors B and D and weak interaction between B and C. Therefore, according to the conducted analysis, A (type of Mo precursor) and D (reaction temperature) have the most significant effect on particle size. Moreover, the optimal process parameter combination for producing of MoS2 nanopowders is obtained as A3B2C3D1 (type of Mo precursor = MoO3, S source type = Na2S, reaction time = 72 h, reaction temperature = 150 ºC). 
The mechanism for the formation of MoS2 powder includes two stages:(1) during the solvothermal phase, it is possible for Mo(VI) to decrease to Mo(IV) by increasing the temperature and pressure, and it then reacts with S; (2) then initial formed MoS2 might instantly aggregate to form small particles.
For example, the overall reaction of synthesizing of MoS2 powder can be expressed when Na2S as the sulfur source is:


Factor contributions
The variance (ANOVA) analysis can be conducted to determine the contribution of each parameter on the grain size. Table 5 summarized the obtained results of the analysis. According to the data tabulated in Table 5, the contribution of the four factors, i.e. reaction temperature, type of molybdenum precursor, type of sulfur precursor, and time of reaction is 40.669%, 27.692%, 21.695%, and 9.941%, respectively. It can be seen that the reaction temperature and type of molybdenum precursor have the most significant effect on the particle size of MoS2 powders compared to the adopted factors.

 

Confirmation run
The confirmation experiment for producing MoS2 nanopowder was carried out via setting the experimental condition of the four parameters as follows: MoO3 for Mo source, Na2S for S source, 72 h, and 150 °C for time and reaction temperature, respectively. Fig. 3 illustrates the SEM micrographs of the MoS2 powder synthesized at the optimal combination of the factors A, B, C, and D. The SEM image of MoS2 synthesized from optimum condition shows sheet like structure so that each particle is composed of multiple lamellar sheets (Fig. 3). The particle size is varying from approximately 20-90 nm. According to the chemical analysis via EDS, the existence of Mo and S is evident (elements of MoS2). 
Moreover, based on the peaks quantification, the atomic ratio of S to Mo is 1.92, which has a very close value to the stoichiometric MoS2 (Fig. 4). The Au signal is aroused from the gold coating of samples before the SEM/EDS test.
Fig. 5 shows the crystalline nature of MoS2 sample prepared at the optimum condition with an XRD pattern indexed at 14.81°, 32.41°, 39.5°, and 58°corresponding to the (002), (100), (103), and (110) crystal planes of the MoS2. In general, the hexagonal 2H-MoS2 can be easily indexed for all the reflections. The presence of the 002 diffraction at 2θ = 14.81° indicates that the sample should be a stacking of single sheets of MoS2 or multiple lamellar sheets [16, 23, 42, 43]. This is in proper agreement with the SEM results.
XPS analysis was used to measure binding energies of Mo and S atom. As shown in Fig. 6b, two asymmetric peaks centred at 229.4 eV and 232.6 eV are due to the transitions of Mo 3d5/2 and 3d3/2, respectively. The S2p curve of MoS2 indicates a strong peak at around 163.9 eV, which is attributed to the coordination of Sulphur and Mo atoms in the structure of MoS2 (Fig. 6c) [44].
Fig. 7 shows the FTIR spectrum of MoS2 powder synthesized in optimum condition in the range 400-4000 cm-1 at room temperature. As seen in this image, the strong band at 469.15 cm-1 assigned to ν(Mo-S). Also, we assign the band at 619.94 and 891.14 cm-1 to ν(O-Mo-O) vibrations and 935.25 cm-1 to ν(Mo=O) vibrations. 
Heat low and gravimetric curves for MoS2 produced in optimum condition are shown in Fig. 8. Nanolamellar optimum MoS2 is stable up to 400 ºC. The more heating of this sample up to 500 ºC due to prime disulfide decomposition into molybdenum and sulfur causes a high weight loss (36%). 
These results support MoS2 powder have been synthesized successfully.

 

CONCLUSION
Taguchi’s experimental design method was utilized to perform the experiments for studying the effects of process factors, including molybdenum precursor, sulfur source, and the reaction temperature and duration on the morphology of the MoS2 powder. The Taguchi orthogonal array is applied to the optimization of the process factors of the synthesis of MoS2 with nano metric size. It is evident that reaction temperature and Mo precursor have a major effect on synthesizing MoS2 nanopowder. The optimized values for producing MoS2 particles with nano sizes are obtained as molybdenum precursor = MoO3, sulfur source= Na2S, reaction temperature = 150 ºC, reaction time= 72 h. SEM image of MoS2 sample synthesized at optimal conditions exhibited the lamellar structure composed of discrete MoS2 nanoparticles with an average crystallite size of about 55 nm. The XRD pattern confirmed the crystal diffraction planes of hexagonal MoS2. FTIR result confirmed Mo-S vibration peak around 470 cm-1. In general, the results of SEM/EDS, XRD, TGA, and FTIR analyses exhibited that nanolamellar MoS2 nanostructures synthesized by a facile hydrothermal route in according to optimal condition proposed by Taguchi design, successfully. And, the next research work will be focused on the investigation of the super-capacitor performance of them.

 

ACKNOWLEDGEMENTS 
This research was supported by the Sayyed Jamaleddin Asadabadi University, Asadabad, Iran. Also, the authors would like to acknowledge the financial support of the Office in Charge of Research of Iranian Nanotechnology Society and the financial support of the Office of Vice chancellor in charge of research of Sayyed Jamaleddin Asadabadi University.

 

CONFLICT OF INTEREST
The authors declare that there is no conflict of interests regarding the publication of this manuscript.

 

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