Microstructure and properties of diamond/SiC composites prepared by tape-casting and chemical vapor infiltration process

This article reported a novel method for preparing diamond/SiC composites by tape-casting and chemical vapor infiltration (CVI) process, and the advantages of this method were discussed. The diamond particle was proved to be thermally stable under CVI conditions and the CVI diamond/SiC composites only contained diamond and CVI-SiC phases. The SEM and TEM results showed a strong interfacial bonding existed between diamond and CVI-SiC matrix. Due to the strong bonding, the surface HRA hardness could reach up to 98.4 (HV 50 ± 5 GPa) and the thermal conductivity (TC) of composites was five times higher than that of pure CVI-SiC matrix. Additionally, the effects of diamond particle size on microstructure and properties of composites were also investigated. With the increasing of particle size, the density and TC of composites with the size 27 μm reached 2.940 g/cm³ and 82 W/(m K), respectively.     

Tape Cast Multilayer Composite of Nano Zirconia with High Toughness

During the last decade, worldwide attention of researchers has focused on nano-ceramic composites with superior mechanical behavior and improved reliability for structural applications. Here we report the development of a multi-layer composite (MLC) of tape cast nano zirconia with high failure energy. The MLC samples were fabricated by thermocompression of green tapes prepared from 3 mole % yttria stabilized zirconia (3-YSZ) powder with a primary crystallite size of 27 nm. Depending on the number of layers, the MLC samples exhibited failure energy (238.97 KJm^-3) more than two times higher than that of the single tape (≈107 KJm^-3) with a reasonably high bi-axial flexural strength (≈630 MPa), high hardness (≈ 13 GPa at 49 N), and indentation fracture toughness nearly four times as high as that of the single tape. In addition, these MLC materials showed the presence of a R-curve behavior.     

Planar proton-conducting ceramic cells for hydrogen extraction: Mechanical properties,electrochemical performance and up-scaling

Proton-conducting ceramics, which selectively separate H₂ from any hydrogen-containing gas could play a role in the future of the growing hydrogen market. In recent years, membrane technologies related to H₂ extraction became attractive solutions to produce pressurized high-purity hydrogen. Yttrium-doped barium zirconate/cerate materials (BaCe_xZr_1-x-yY_yO_3-δ) are among the most studied and used materials. In this study, symmetrical cells consisting of a protonic electrolyte (BaCe_0·2Zr_0·7Y_0·1O_3-δ (BCZY27), 10–15 μm in thickness) surrounded by two cermet electrodes (BCZY27–Ni (50?50 vol%), 150 μm) were prepared for H₂ extraction applications. The cells were prepared via tape-casting and co-sintered at 1575 °C. The cells were up-scaled to an area of 135 cm². The fracture toughness of the cermet electrodes was determined to be 2.07 (±0.05) MPa · m^1/2 at room temperature using the double torsion technique. Impedance spectra were recorded on the symmetrical cells between 650 and 800 °C in 3% humidified 50% H₂/50% N₂ atmosphere and at 650 °C varying the hydrogen partial pressure (20% < pH₂<100%). In 50% H₂/50% N₂ with 3% H₂O the cells demonstrated an ohmic resistance of 0.59 and 0.44 Ω cm,² an average electrode polarization resistance of 0.10 and 0.09 Ω cm² (per one electrode) at 650 and 800 °C, respectively. Moreover, a stability test was performed over 400 h highlighting the stable electrochemical properties of the symmetrical membranes.     

Fabrication and characterization of planar-type SOFC unit cells using the tape-casting/lamination/co-firing method

In this study, solid oxide fuel cells (SOFCs) consisting of a NiO-YSZ anode, a NiO/YSZ-YSZ functional layer, YSZ electrolyte and a (La_0.8Sr_0.2)MnO₃ + yttria-stabilized zirconia (LSM-YSZ) cathode were fabricated by tape-casting, lamination, and a co-firing process. NiO/YSZ-YSZ nano-composite powder was synthesized for the anode functional layer via the Pechini process in order to improve cell performance. After optimization of the slurries for the anode functional anode, electrolyte and cathode, all components were casted so as to fabricate the monolithic laminate. The co-firing temperature was optimized to minimize second phase formation between the (La_0.8Sr_0.2)MnO₃ (LSM) and yttria-stabilized zirconia (YSZ) and to increase the sinterability of the YSZ electrolyte. The YSZ electrolyte was fully sintered with the addition of 0.5 wt% CuO, and the second phases of La₂Zr₂O₇ and SrZrO₃ did not form at 1350 °C. Ni-YSZ anode-supported unit cells were fabricated by co-firing at 1250-1400 °C. The unit cells co-fired at 1250 °C, 1300 °C, 1325 °C, 1350 °C and 1400 °C had maximum power densities of 0.18, 0.18, 0.30, 0.46 and 0.036 W/cm², respectively, in humidified hydrogen (∼3% H₂O) and air at 800 °C.     

Applications of nano-composite materials for improving the performance of anode-supported electrolytes of SOFCs

In order to improve the performance of the anode-supported electrolyte of solid oxide fuel cells (SOFCs), the anode electrode is modified by inserting an anode functional layer of nano-composite powders between a Ni–YSZ electrode and YSZ electrolyte. The NiO–YSZ nano-composite powders are fabricated by coating nano-sized Ni and YSZ particles on the YSZ core particle by the Pechini process. The reduction of the polarization resistance of a single cell that is applied to the anode functional layer is attributed to the increasing reaction of three-phase boundaries (TPBs) within the layer and the micro-structured uniformity in the electrode. Two methods were used, namely tape-casting/dip-coating and tape-casting/co-firing, for studying the performance. It can be concluded that the cell with an anode functional layer thickness (15–20 μm) and a microstructure of NiO–YSZ nano-composite materials which was fabricated by the tape-casting/dip-coating method improved the output power (to 1.3 W cm⁻²) at 800 °C using hydrogen as fuel and air as an oxidant.     

Fabrication of integrated BZY electrolyte matrices for protonic ceramic membrane fuel cells by tape-casting and solid-state reactive sintering

Integrated porous/dense/porous tri-layer BaZr_0.8Y_0.2O_3-δ (BZY) electrolyte asymmetrical matrices were designed for protonic ceramic membrane fuel cells (PCMFCs) and fabricated by multilayer tape-casting and solid-state reactive sintering. The effects of pore-former, sintering aid and sintering program on the microstructure of integrated electrolyte matrices (IEMs) were studied. Graphite and NiO were appropriate pore-former and sintering aid, respectively, and an accelerated heating program was more desirable. The conductivities of the IEM with designed microstructure in different atmospheres were measured by AC impedance spectroscopy at 400–600 °C. The highest conductivity of 6.9 × 10^?3 S cm^?1 at 600 °C was obtained in wet air atmosphere, and the corresponding activation energy was 0.602 eV. Gas-tightness of the IEM was confirmed by a stable open circuit voltage (OCV) of 0.97 V at 600 °C from a button fuel cell with impregnated NiO anode and BaCo_0.4Fe_0.4Zr_0.1Y_0.1O_3-δ (BCFZY) cathode. These indicate that the fabricated BZY-based IEM has great potential for PCMFC application.     

Development of solid oxide fuel cells (SOFCs) by tape-casting and single-step co-firing of monolithic laminates

We developed a cost-effective method to manufacture high performance-monolithic solid oxide fuel cells using nano-composite electrodes, tape-casting and single-step co-firing.     

Influence of the aging time of yttria stabilized zirconia slips on the cracking behavior during drying and green properties of cast tapes

Tape-casting process was used to produce yttria stabilized zirconia (YSZ) substrates in an aqueous system using a low amount of an acrylic latex binder. Concentrated suspensions with different aging times were cast, and the influence of the slip aging time on the drying kinetics and cracking behavior of the tapes were studied. In addition, the effect of the slip aging time on the properties of the resultant green tapes was investigated. The latex particles consolidated by coalescence during the aging time of the slips and resulted in an increase in the smaller pore size of the cast tapes. The pore radius increased with increasing the slip aging time up to 14 days thereby decreasing the capillary pressure in the liquid. Aging times over 14 days did not change the pore radius and consequently the capillary pressure. The capillary tension drove the consolidation; the tapes produced from slips with lower aging times which had higher capillary pressure shrank more, had lower pore volume and consequently higher green density. Cracking was found in tapes prepared from slips with aging times shorter than 14 days; the crack area decreased with increasing the slip aging time. For slip aging time ≥14 days cracking was not observed. Aging before casting up to 14 days reduced cracking in tapes prepared with low amounts of latex; however, the lower capillary pressure resulted in low green density of the cast tapes.     

Synthesis and characterization of NiO/GDC–GDC dual nano-composite powders for high-performance methane fueled solid oxide fuel cells

GDC (gadolinium-doped ceria) is well known as a high oxygen ionic conductor and is a catalyst for the electrochemical reaction with methane fuel leading to the oxidation of deposited carbon that can clog the pores of the anode and break the microstructure of the anode. NiO/GDC–GDC dual nano-composite powders were synthesized by the Pechini process, which were used as an AFL (anode functional layer) or anode substrates along with a GDC electrolyte and LSCF–GDC cathode. The anodes, AFL, and electrolyte were fabricated by a tape-casting/lamination/co-firing. NiO–GDC anode and NiO/GDC–GDC anode-supported unit cells were evaluated in terms of their power density and durability. As a result, the NiO/GDC–GDC dual nano-composite demonstrated an improved power density from 0.4 W/cm² to 0.56 W/cm² with H₂ fuel/air and from 0.3 W/cm² to 0.56 W/cm² with CH₄ fuel/air at 650 °C. In addition, it could be operated for over 500 h without any degradation with CH₄ fuel.     

AlN基片流延浆料粘度的研究

本文研究了影响AIN流延浆料粘度的主要因素,结果表明,环境温度或溶剂比例的增加,浆料的粘度值下降,而较细的粒度和增塑剂的减少则使粘度上升。本文还指出了严格控制各影响因素以实现稳定流延工艺的必要性。