Manufacturing catalyst-coated membranes by ultrasonic spray deposition for PEMFC: Identification of key parameters and their impact on PEMFC performance

This study deals with the manufacturing of catalyst-coated membranes (CCMs) for newcomers in the field of coating. Although there are many studies on electrode ink composition for improving the performance of proton-exchange membrane fuel cells (PEMFCs), there are few papers dealing with electrode coating itself. Usually, it is a know-how that often remains secret and constitutes the added value of scientific teams or the business of industrialists. In this paper, we identify and clarify the role of key parameters to improve coating quality and also to correlate coating quality with fuel cell performance via polarization curves and electrochemical active surface area measurements. We found that the coating configurations can affect the performance of lab-made CCMs in PEMFCs. After the repeatability of the performance obtained by our coating method has been proved, we show that: (i) edge effects, due to mask shadowing - cannot be neglected when the active surface area is low, (ii) a heterogeneous thickness electrode produces performance lower than a homogeneous thickness electrode, and (iii) the origin and storage of platinum on carbon powders are a very important source of variability in the obtained results.     

Electrochemical performance of spherical Li-rich LMNCO cathode materials prepared using a two-step spray-drying method

In this study we synthesized Li-rich Li_1.2Ni_0.13Mn_0.54Co_0.13O₂ (LMNCO) as a composite cathode material through a two-step spray-drying method, using transition metal (TM) acetates and citric acid (CA, as a chelating agent) at various molar ratios and then calcining at various temperatures for various periods of time. This two-step spray-drying method created hierarchical nano/micro-sphere structures of the LMNCO cathode material. The LMNCO cathode exhibited the best electrochemical performance when synthesized with a TM:CA ratio of 3:2, a calcination temperature of 900 °C, and a calcination time of 5 h. This as-prepared LMNCO composite was then modified with polyimide (PI) at various weight ratios (PI/LMNCO = 0.5, 1.0, and 1.5 wt%) to improve its electrochemical properties. Among the various structures, the LMNCO cathode material coated with 1.0 wt% of PI at a layer thickness of approximately 1.88 nm achieved the best initial discharge capacities. This modified electrode also displayed enhanced cycle stability, with over 93.3 and 87.9% of the capacity retained after 30 cycles at 0.1C and 100 cycles at 1C, respectively. In comparison, the capacity retention of the unmodified LMNCO electrode measured under the same conditions was no more than 91.3% at 0.1C and 70.1% at 1C. Thus, surface modification with PI was an effective method for improving the coulombic efficiency, discharge capacity, and long-term cycling performance of the LMNCO cathode. Such PI-coated LMNCO composite cathode materials appear to be potential candidates for use in next-generation high-performance lithium-ion batteries.     

A Ti3C2Tx-carbon black-acrylic epoxy coating for 304SS bipolar plates with enhanced corrosion resistant and conductivity

A conducting and anticorrosive coating is crucial for the application of metal bipolar plates (BP) in proton exchange membrane fuel cell (PEMFC). In this work, a Ti₃C₂T_x (T)-carbon black (C)-acrylic epoxy (AE) coating is prepared on 304 stainless steel (SS) with enhanced corrosion resistance and conductivity. The corrosion resistance of the T-C-AE coating is investigated in a 0.5 M H₂SO₄ solution as compared to the AE, T, and T-AE coatings. The T-C-AE coated 304SS exhibits the strongest corrosion resistance with the most positive corrosion potential and the lowest corrosion current density of 0.00673 μA cm^?2 in all the samples, while retaining intact and compact surface morphology with the lowest metal ion dissolution even after immersed for 720 h. The addition of Ti₃C₂T_x and carbon black into the AE matrix greatly decreases interfacial contact resistance (ICR), and the T-C-AE coating achieves a low ICR of 15.5 mΩ cm^?2 under 140 N cm^?2 compaction force. The excellent anticorrosion performance is mainly attributed to the physical barrier and the cathodic protection provided by the stacked Ti₃C₂T_x (MXene) nanosheets in the T-C-AE coating. This eco-friendly, conducting, and anticorrosive T-C-AE coating has a good application prospect on SS BP of PEMFC.     

Use of La2O3 with 8YSZ as thermal barrier coating and its effect on thermal cycle behavior,microstructure, mechanical properties and performance of diesel engine operated by hydrogen-algae biodiesel blend

In this present work, the effect of lanthanum oxides (La₂O₃) on the thermal cycle behavior of TBC coatings and mechanical properties such as adhesion strength and microhardness of 8% Yttria Stabilized Zirconia (8YSZ) TBCs were investigated. CoNiCrAlY and aluminium alloy (Al–13%Si) were used as bond coat and substrate materials. 8YSZ and different wt % of La₂O₃ (10, 20, and 30%) top coatings were applied using the atmospheric plasma spray (APS) method. The thermal cycling test for TBC coated samples were conducted at 800 °C in the electric furnace. The XRD pattern shows that the La₂O₃ doped 8YSZ material transformed to cubic pyrochloric structured La₂Zr₂O₇ during thermal cycling. Further, the Taguchi-based grey relation analysis (GRA) method was applied to optimize the TBC coating parameters to achieve better mechanical properties such as adhesion strength and microhardness. And the optimized La₂O₃/8YSZ TBC coating was coated on CRDI engine combustion chamber components. The engine was tested with microalgae biodiesel and hydrogen, and the results were promising for the TBC-coated engine. The engine performance increased while using La₂O₃/8YSZ coated components, and the emissions from engine exhaust gas such as CO, HC, and smoke reduced considerably. It was found that there was no separation crack and spallation of the coating layer in the microstructure. Ultimately, the microstructural analysis of the optimized TBC coated piston sample after 50 h of running in the diesel engine confirmed that the developed coating had a superior thermal insulation effect and longer life.     

Laser damage resistance of plasma-sprayed alumina and honeycomb skeleton/alumina composite ceramic coatings

Al₂O₃ and honeycomb skeleton-Al₂O₃ composite coatings on Titanium alloy (Ti–6Al–4V) were prepared by atmospheric plasma spraying. A laser ablation experiment on as-sprayed coatings was performed. In this paper, the laser damage resistance, microstructure, phase composition of Al₂O₃ coatings were examined. 3D Dimensional Confocal Microscopy, Scanning Electron Microscopy (SEM), X-ray Diffraction (XRD), and Energy Dispersive Spectrometry (EDS) characterized the laser damage morphology, microstructure, phase composition, and element analysis, respectively. The influence of the honeycomb skeleton on the laser ablation damage on as-sprayed coatings was investigated by a comparative analysis of the laser damage morphology with different laser ablation times and gas flow. The results show that the honeycomb skeleton raises thermal conductivity and thermal diffusivity. Moreover, a “tower”-like dendrite was generated during the laser irradiation of the composite coating. The honeycomb skeleton refined the structure, suppressed crack propagation, and reduced the influence of gas flow on cracks. Under the same experimental laser ablation parameters, the laser damage area of the honeycomb skeleton-Al₂O₃ composite coating was smaller than that of the Al₂O₃ coating. It was demonstrated that the laser damage resistance of the honeycomb skeleton-Al₂O₃ composite coating was superior to that of the Al₂O₃ coating.     

Synthesis and characterization of ZnO NRs with spray coated GO for enhanced photocatalytic activity

Zinc oxide nanorods, ZnO NRs, were synthesized on a clean glass and coated with graphene oxide (GO) using spray coating method to enhance the photocatalytic activity in wastewater treatment. The ZnO NRs were synthesized using the solution process synthesis that was optimized using Taguchi method. Several synthesis parameters have been optimized and studied to determine the best synthesis parameter to grow ZnO NRs for the photodegradation of organic contaminants. Field emission scanning electron microscopy (FESEM) with EDX, X-ray diffraction (XRD), Raman, ultraviolet visible near-infrared (UV-VIS-NIR), and photoluminescence (PL) spectroscopies were used to investigate the structural and optical properties of the produced nanorods. FESEM images revealed the vertical growth of ZnO NRs as well as layers of GO covering the ZnO NRs' top surface. The Raman study demonstrates the combination peak of GO and ZnO, hence proving the GO layer's successful coating. After the GO coating, decrease in the bandgap of the synthesized photocatalyst was detected by PL and UV–Vis absorption measurements. Under UVC exposure with treatment time of 6 h, the degradation of MB with ZnO NRs/GO photocatalyst reached a degradation percentage of 97.86%, which is greater than the degradation percentage achieved using pristine ZnO NRs, which is 93.28%. The results validated that the coating of GO enhances the photocatalytic activity of the host material, ZnO NRs.     

Synthesis,microstructures, and corrosion behaviors of multi-components rare-earth silicates

Multi-components and equimolar rare earth monosilicates, (Y_1/3Dy_1/3Er_1/3)₂SiO₅, (Y_1/3Dy_1/3Lu_1/3)₂SiO₅, (Y_1/4Dy_1/4Ho_1/4Er_1/4)₂SiO₅ and (Yb_1/4Dy_1/4Ho_1/4Er_1/4)₂SiO₅, were prepared by solid-state reactions and the following hot-pressing. Dense microstructures with uniform elemental distributions were obtained for all samples. These investigated multi-components monosilicates exhibit low thermal conductivities and similar coefficients of thermal expansion with SiC. Moreover, they exhibit high corrosion resistances in 1400 °C water vapor, especially, four-components (Y_1/4Dy_1/4Ho_1/4Er_1/4)₂SiO₅ and (Yb_1/4Dy_1/4Ho_1/4Er_1/4)₂SiO₅ experienced almost invariable weights after small weight losses during the initial 0.5 h. All those results indicate that multi-components rare earth monosilicates are promising candidates of environmental barrier coatings for SiC/SiC composites.     

Influence of SiC dispersion and Ba(Sr) substitution on the thermoelectric properties of Ca3Co4O9+δ

Ca₃Co₄O_9+δ is a typical p-type thermoelectric oxide material with a low thermal conductivity. In this study, double-layered oxide samples Ca(Ba,Sr)₃Co₄O_9+δ dispersed with different SiC contents were obtained via the traditional solid phase reaction method. The effects of different elemental substitutions and SiC dispersion contents on the microstructure and thermoelectric properties of the samples were studied. The double optimisation of partial substitution of Ca-site atoms and SiC dispersion considerably improved the thermoelectric properties of Ca₃Co₄O_9+δ. Through the elemental substitution, the resistivity of the Ca₃Co₄O_9+δ material was reduced. Conversely, introducing an appropriate amount of SiC nanoparticles enhanced phonon scattering and was crucial in reducing its thermal conductivity. After double optimisations, the dimensionless thermoelectric figure of merit (ZT) values of both Ca_2.93Sr_0.07Co₄O_9+δ + 0.1 wt% SiC and Ca_2.9Ba_0.1Co₄O_9+δ + 0.1 wt% SiC achieved an optimum value of 0.25 at 923 K.     

Fabrication and properties of the superhydrophobic ceria-based composite coating on magnesium alloy

A superhydrophobic ceria-based composite coating is developed to improve anticorrosion properties of AZ61 magnesium alloy, fabricating via chemical conversion method followed by hydrothermal treatment. The cerium conversion coating has a block structure with microcracks. After the hydrothermal treatment, a dense CeO₂ layer, porous CeO₂ nanorods, and stearic absorbing layers are grown stepwise on the conversion coating. And the composite coating is hydrophobic or even superhydrophobic and has almost no microcracks. As the hydrothermal reaction time increases, the water contact angle of the composite coating first increases and then decreases, and it reaches the maximum value of 152° after hydrothermal treatment for 4 h. Both the dense CeO₂ layer and the superhydrophobic stearic absorbing layer can effectively prevent the electrolyte from contacting the substrate; the corrosion current density of the superhydrophobic composite coating is lower than that of the hydrophilic composite coating and the cerium conversion coating, and has the best corrosion resistance.     

Altered age-hardening behavior in the ultrafine-grained surface layer of Mg-Zn-Y-Ce-Zr alloy processed by sliding friction treatment

To gain insight into the ageing behavior of ultrafine grain(UFG)structure,the precipitation phenom-ena and microstructural evolutions of Mg-6Zn-1Y-0.4Ce-0.5 Zr(wt.％)alloy processed by sliding friction treatment(SFT)were systematically studied using hardness texting,transmission electron microscopy(TEM)equipped with high-angle annular dark-field scanning(HADDF-STEM),X-ray diffraction(XRD)and XRD line broadening analysis.The microhardness of the SFT-processed(SFTed)sample initially decreases from 109.6 HV to 104.8 HV at ageing for 8 h,and then increases to the peak-ageing point of 115.4 HV at 16 h.Subsequently,it enters the over-aged period.The un-SFTed sample,as the counterpart,follows a regular ageing behavior that increases from 89.9 HV to 99.6 HV when ageing for 12 h,and then drops.A multi-mechanistic model is established to describe the strengthening due to grain refinement,disloca-tion accumulation,precipitation etc.The analysis reveals that the temperature sensitive UFG structure has an obvious grain coarsening effect,which arouses the soft phenomenon in the early ageing stage.But precipitation hardening provides an excellent hardness enhancement for overcoming the negative influ-ence and helping to reach the peak-aged point.In our microstructural observations,a lot of equilibrium ultrafine MgZn2 precipitates precipitate along dislocations because defects can provide the favorable conditions for the migration and segregation of solute atoms.