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At least 1,171 records · Page 65

Microstructure evolution of gadolinium doped cerium oxide under large thermal gradients

In this report the effects of large thermal gradient annealing on the microstructure of 10 mol% gadolinium doped ceria (GDC) were investigated. GDC powder was prepared by solvent deficient method and sintered at 1650 °C for 10 h to achieve dense ceramics with ~8 μm grain size. The densified GDC samples were subsequently annealed using a 60 W infrared laser at over 2100 °C for 1 h under a thermal gradient equivalent to ~0.3–0.5 °C/μm. The post-annealed samples at 2150 °C for 1 h exhibit grains with average length and width of 37 and 28 μm, respectively. Electron backscattered diffraction (EBSD) analysis revealed that the post-annealed sample at 2150 °C consists of grains oriented close to five principal directions (<4 3 10>, <0 0 1> and <13 1 14> on [0 0 1], and <7 6 20> and <7 2 7> on [0 1 0]) within a tolerance angle of ±10°, whereas the grains of the pre-annealed sample are randomly oriented. Gadolinium diffuses 20–30 μm away from the irradiated surface, with the measured composition of regions deeper than 30 μm, Ce 0.86 Gd 0.14 O 1.93 , is close to that of the pre-annealed sample, Ce 0.87 Gd 0.13 O 1.94 . Enhancement of total conductivity of the post-annealed GDC (1.1 × 10 -3 S cm -1 at 500 °C, and 2.1 × 10 -2 S cm -1 at 700 °C) is observed when compared to the pre-annealed GDC (3.1 × 10 -5 S cm -1 at 500 °C, and 1.7 × 10 -3 S cm -1 at 700 °C), and points to the decrease in the grain boundary (GB) resistivity. This could be attributed to both the change in GB area and grain alignment.

36 MATERIALS SCIENCE↗

Synthesis of nanograined zirconium diboride microsphere powder feedstock via emulsification of suspensions

Ceramic nanograined materials have desirable characteristics compared to their macroparticle counterparts but are rarely used in industrial applications due to issues with poor handleability and health hazards. Due to interparticle forces that become more dominant as the particle size decreases, it is difficult to use nanomaterials to fill dies, spread on surfaces, or flow through hoppers found in various manufacturing processes. In this work, we report a scalable gelcasting solution and unique emulsification process to create microspheres composed of nanoscale powders to enhance the flowability and handleability of nanomaterials. The gelcasting solution and emulsification process can be used with any nanoparticle composition that can be suspended in a liquid phase. This paper reports the effects of various parameters on zirconium diboride microsphere formation, such as surfactant content and mixing conditions. The microspheres maintain the nano-scale characteristics of the powder but improve its flowability by using cross-linked polyvinyl alcohol to combine irregularly shaped zirconium diboride nanoparticles with a particle diameter of 60 nm into larger spherical particles with a d 50 ~25 μm. This hierarchical feedstock engineering design combine the positive characteristics of materials across both length scales and improve the flowability of the feedstock from a Hausner Ratio of 1.56 to 1.19. The materials produced using this technique can be used in thermal plasma spray, die filling for hot pressing or spark plasma sintering, and binder jet printing applications.

36 MATERIALS SCIENCE↗

Additive manufacturing of continuous carbon fiber-reinforced SiC ceramic composite with multiple fiber bundles by an extrusion-based technique

Due to the high cost, complex preparation process and difficulty in structural design, the traditional methods for carbon fiber-reinforced SiC ceramic composite preparation have great limitations. This paper presents a technique for the additive manufacturing multiple continuous carbon fiber bundle-reinforced SiC ceramic composite with core-shell structure using an extrusion-based technique. A conventional nozzle system was modified to print simultaneously a water-based SiC paste with continuous carbon fibers. Different levels of binder contents were investigated to optimize the stickiness, viscosity, thixotropy and viscoelasticity of the paste. After sintering, SiC whiskers were generated on the surface of fiber, which is conjectured to be due to the reaction between SiO and carbon fiber at high temperature. The continuous carbon fiber-reinforced SiC ceramic composite exhibited non-brittle fracture. In conclusion, the flexural strength of the additively manufactured Cf/SiC composites improved from 162 MPa with no fiber bundles to a maximum of 219 MPa with three fiber bundles.

36 MATERIALS SCIENCE↗

Chemical durability of multicomponent lanthanide zirconate solid solutions

Multicomponent zirconate solid solutions A 2 Zr 2 O 7 (A= (Sm,Yb), (Sm,Yb,Gd), (Sm,Yb,Gd,Er), and (Sm,Yb,Gd,Er,Dy)) were synthesized through spark plasma sintering and their chemical durability was investigated via semi-dynamic leaching tests in pH = 1 nitric acid at 90°C. Incongruent dissolution occurred for all samples with the preferential elemental release of zirconium in all A 2 Zr 2 O 7 except for high entropy (Sm,Yb,Gd,Er,Dy)Zr 2 O 7 which displays a congruent release of the A-site elements and Zr. A strong positive correlation was found between the lanthanide elemental release rates and the A-site cation size disorder, whereas a negative correlation was observed between the elemental release rates and mixing entropy.

36 MATERIALS SCIENCE↗

Investigation of B 4 C for inhibiting crystallization in silica at high temperatures

Amorphous silica has numerous high temperature applications due to its inherent thermal shock resistance and low coefficient of thermal expansion (CTE). However, at the high temperatures required for processing (>1200 °C), the metastable β-cristobalite phase preferentially forms and is accompanied by a volume change, and potential cracking, upon conversion to the low temperature α-cristobalite phase. The CTE of the final crystalline phase is an order of magnitude higher than its amorphous counterpart. Here experimental results demonstrate that small additions of B 4 C (3.5 wt%) effectively inhibit silica crystallization in powder and sintered gel-cast forms up to 22h at temperatures as high as 1500°C as confirmed via x-ray diffraction. Further, the oxidation of B 4 C to B 2 O 3 and its subsequent melt and evaporation disrupts the nucleation and growth of the cristobalite phase. The mechanism for crystallization inhibition is further explored through optical microscopy to probe changes in surface morphology.

36 MATERIALS SCIENCE↗

Exploring laser-material interactions of zirconium carbide under additive manufacturing conditions

Zirconium carbide (ZrC) is an ultra-high temperature ceramic with a melting temperature above 3000°C and a broad range of high temperature applications. Given the high melting and sintering temperatures of pure ZrC, producing near-net shape and fully dense parts remains challenging with conventional techniques. In this study, we investigate the fundamental laser-material interactions of ZrC under laser powder bed fusion (LPBF) additive manufacturing (AM) conditions. Normalized enthalpy, a scaling law term that is used in welding and AM literature for detailing laser-material interactions in metallic alloys, was calculated to determine the predictive capabilities of melt pool features in ZrC. Further, the melt pool quality of laser irradiated ZrC was used to compare LPBF relevant laser parameter combinations of laser power, scan speed, and beam diameter. Laser build parameters that resulted in desirable melt pool morphologies were applied to the fabrication of ZrC coupons using LPBF AM. A custom LPBF system was used to determine hatch spacing and layer height parameters that resulted in a fabricated sample with a density of 85% as measured by Archimedes and a Vicker's microhardness of 20.9 ± 1.9 GPa. This investigation reveals the laser-material interactions of ZrC under AM relevant conditions and is the first step towards LPBF fabrication of ZrC parts.

36 MATERIALS SCIENCE↗

Microstructural characterization and equibiaxial flexural strength of CeO 2 and Ti-doped CeO 2

In this study, the synthesis of CeO 2 and titanium dioxide (TiO 2 ) doped CeO 2 (TDC) monoliths are investigated, and their fracture strength is assessed using an equibiaxial flexure testing technique at room temperature. Pellets were synthesized using conventional powder processing and sintering methods to produce the desired characteristics. The TiO 2 dopant concentration was optimized at 0.1 wt % TiO 2 to obtain dense, solid-solution pellets with an enhanced grain microstructure. A ball-on-ring fixture was used to obtain the TRS and Weibull parameters of over 30 pellets for CeO 2 and 0.1 wt % TDC to compare fracture behavior. The TRS of CeO 2 pellets ranged from 88 to 160 MPa and the TRS of 0.1 wt % TDC pellets ranged from 102 to 171 MPa, both being consistent with published values. Weibull parameters, such as characteristic strength and Weibull modulus, were extracted as 129 MPa and 8.5 for CeO 2 and 150 MPa and 9.3 for 0.1 wt % TDC, respectively. Although Hertzian contact damage was observed on compressive surfaces, failure initiation occurred on the tensile surfaces of both types of samples. Fracture surface analysis for CeO 2 indicated a predominantly intergranular fracture while 0.1 wt % TDC had a predominantly transgranular fracture mode. Finally, the TRS of 0.1 wt % TDC resulted in increased Weibull parameters when compared to CeO 2 , indicating sample chemistry and microstructure impact mechanical behavior for these samples.

36 MATERIALS SCIENCE↗

Current activated reactive ultrafast joining (CARUJ) of silicon carbide

In this work we propose and demonstrate a novel approach for rapid fabrication of ceramic-ceramic joint assemblies, using sintered Silicon Carbide (SiC) as an initial example. Current Activated Reactive Ultrafast Joining (CARUJ) utilizes resistive heating of carbon-based materials to apply localized heat at or around the joint zone at heating rates of 101– 103 °C/min. CARUJ is used to fabricate SiC-SiC joints with a Si-SiC interface using minimal pressure (1–2 MPa) at time scales considerably shorter (several minutes opposed to hours) than conventional approaches for similar systems. The reaction of an interfacial precursor based on elemental silicon and carbon leads to in-situ SiC formation to produce a continuous and dense bond in a single step. Measured average joint strengths of roughly 15 MPa are achieved when tested in single lap offset (SLO) compressive shear. Optional additions of refractory metals such as molybdenum can be utilized to introduce secondary inclusions such as MoSi 2 within the joint interface. We further demonstrate SiC-SiC joining using Active Brazing Alloys (ABA) and proof of concept joining of tubular geometries. The localized and rapid heat application realizes a versatile material joining technique that could be extended for joining components at the plant site.

36 MATERIALS SCIENCE↗

Packing density optimization and recyclability of multi-modal SiC powder feedstocks in binder jet additive manufacturing

Achieving high powder packing density is critical in binder jet additive manufacturing (BJAM), as it directly influences the final part density, mechanical properties, and sintering behavior. Multi-modal powder blends, which combine particles of different sizes, have been explored as a strategy to optimize packing efficiency and minimize defects. In this study, bimodal and trimodal powder blends were obtained by mixing silicon carbide powder in three different sizes. These results show that increased powder density is achievable with bimodal powder blends but is reduced in trimodal blends, and it was found that a 13 % increase in the powder tap density was achieved using a bimodal blend of powder. The powder size distribution of the bimodal blend was measured at various stages during binder jet additive manufacturing and, no measurable powder separation occurred even after eight prints. Altogether, this study shows limited advantage to trimodal powder blends but good promise for bimodal blends for increasing printed density while maintaining reusability in the binder jet process.

Aguirre, Trevor G. [Oak Ridge National Laboratory ↗

A systematic study of lanthanide titanates (A 2 Ti 2 O 7 ) chemical durability: corrosion mechanisms and control parameters

Dense lanthanide titanates ranging from La 2 Ti 2 O 7 to Yb 2 Ti 2 O 7 were synthesized by spark plasma sintering with similar micro-sized microstructure, and their chemical durability and degradation mechanisms were investigated by semi-dynamic leaching tests. Different corrosion mechanisms from incongruent to congruent dissolution were observed with preferential elemental releases of lanthanides in A 2 Ti 2 O 7 (A = La to Gd) and Ti in Er 2 Ti 2 O 7 and Yb 2 Ti 2 O 7 . Initial leaching was controlled by surface dissolution and long-term dissolution shifted to a diffusion-controlled mechanism for titanate pyrochlores from Sm 2 Ti 2 O 7 to Yb 2 Ti 2 O 7 . Both short-term and long-term leaching rates decreased from La 2 Ti 2 O 7 to Yb 2 Ti 2 O 7 , and materials became more corrosion resistant with decreasing ionic radius ratios of the rare-earth elements and titanium. Amorphous passivation films of several nm-thick enriched with Ti formed on the surfaces of the corroded materials, and the formation mechanisms were governed either by surface reorganization with preferential release of lanthanides or dissolution-precipitation from saturated bulk solutions with preferential release of titanium. Finally, these results demonstrate that the ionic size plays a dominant role in determining chemical durability of lanthanide titanates and a strong correlation is established among chemical composition/structural variation, passivation film formation and corrosion mechanisms, and materials chemical durability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Novel structured Sm 0.5 Sr 0.5 CoO 3-δ cathode for intermediate and low temperature solid oxide fuel cells

The performance of solid oxide fuel cell (SOFC) can be significantly enhanced using nanostructured cathode obtained by infiltration/impregnation method. However, this method has been limited due to multi-step preparation process and instability of the obtained nanoscale catalyst under long-term operation. We report here a simple, cost-effective and reproducible approach to fabricate nanostructured Sm 0.5 Sr 0.5 CoO 3-δ (SSC) cathode with enhanced performance and stability. The SSC powders were prepared by a freeze-drying method through a combustion route using Pluronic F-127 as the template. The SSC freeze-drying powders have unique morphology and a significant phase change at 750 °C. The oxygen non-stoichiometry (δ) of the SSC powders is 0.18 at room temperature, while the δ values are 0.66, 0.75 and 0.90 at 600 °C, 700 °C and 800 °C, respectively. The novel structured SSC cathode was prepared by screen-printing and one-step sintering process using the freeze-drying SSC powders. Maximum cell power densities of 0.83 and 1.13 W cm -2 are achieved at 550 °C and 600 °C, respectively for single cells with the novel structured SSC cathode. Moreover, single cells show excellent stability at 600 °C under a current density of 600 mA cm -2 over 250 h. This work expands opportunities to exploit nanotechnology in a wide range of intermediate and low temperature energy conversion devices.

25 ENERGY STORAGE↗

Locally developed electronic conduction in a yttria stabilized zirconia (YSZ) electrolyte for durable solid oxide fuel cells

In the present work, anode supported solid oxide fuel cells (SOFCs) based on a YSZ single layer electrolyte with locally developed electronic conduction near the anode side is fabricated to improve the cell durability under negative voltage conditions. A ceria added Ni/YSZ anode functional layer is utilized and co-sintered with the YSZ electrolyte at 1460 °C. Cerium ions are diffused into a limited region of the YSZ layer (~6 μm), establishing a ceria doped YSZ region. We successfully demonstrate that this YSZ single layer cell can operate stably for ~100 h without anode/electrolyte interface delamination, even under a negative voltage. The embedded probe technique and theoretical calculation reveal that the internal oxygen partial pressure (near the anode) is substantially reduced (stabilized) by means of local electronic conduction of ceria doped YSZ. Thus, we propose an SOFC electrolyte design comprising a YSZ single layer with a ceria added anode functional layer (locally formed ceria doped YSZ in the electrolyte) as a protection method against fuel cell stack degradation caused by negative voltage operation.

25 ENERGY STORAGE↗

Enhancement of low-temperature solid oxide fuel cell performance and durability via surface chemistry modification

The development of active cathodes is one of the most critical challenges to lowering the operating temperature for solid oxide fuel cells (SOFCs). Here, in this work, we demonstrated that by modifying the cathode surface chemistry at a relatively low temperature, the cathode activity and durability can be simultaneously enhanced on high-performing, low-temperature cathodes such as (La 0.6 Sr 0.4 ) 0.95 Co 0.2 Fe 0.8 O 3-δ (LSCF) and Sr 0.5 Sm 0.5 CoO 3-δ (SSC). This low-temperature modification using multi-valent cations activates the highly defected surface and maintains the nanoscale electrocatalysts by bypassing the high-temperature sintering procedure for SOFC fabrication. The modified cathode at 600°C shows an order of magnitude reduction in impedance to only 0.05 Ωcm 2 with a peak power density of 1.1 W/cm 2 and increases stability over 2000 h. The combination of in situ characterization, distribution of relaxation time analysis on impedance spectroscopy, and surface chemistry analysis reveals the importance of surface chemistry control on the gas-solid reaction activity and durability and provides the design principle for numerous future solid oxide cells.

25 ENERGY STORAGE↗

Effect of cell compression on the performance and the structure of proton exchange membrane water electrolyzer (PEMWE) assembly

Here, in the field of water electrolysis, the proton exchange membrane water electrolyzer (PEMWE) is currently the most advanced technology for producing hydrogen without emitting CO 2 . Although PEMWE plants are already in operation, further research is needed to improve cell efficiency and reduce the use of rare materials, such as iridium oxide catalysts for the oxygen evolution reaction (OER). One of the main causes of performance loss in PEMWE is the relatively low electric conductivity of the porous transport layer (PTL) and of the anode catalyst layer, which results in ohmic losses and low catalyst utilization during high current density operation. The objective of this study is to investigate how optimization of the PTL and electrode interface can increase the cell performance. To this end, we tested different cell assemblies using fibrous and sintered PTLs, decreasing membrane thickness, reducing iridium loading, and inserting a microporous layer to increase contact surface area. Electrochemical characterization of each cell configuration was systematically performed at various compression levels as the pressure is a crucial parameter influencing the electrode/PTL contact area. In parallel, X-ray microcomputed tomography (micro-CT) was employed to investigate the effects of cell hydration and compression on the structure of PEMWE components. This study combining electrochemistry and micro-CT imaging presents how optimizing the electrode/PTL contact surface area, minimizes ohmic losses, and enables PEMWE operation with low iridium loading at high current densities.

Catalyst - PTL interface↗

On the solid-state-bonding mechanism in friction stir welding

This study is a critical assessment of various solid-state-bonding mechanisms is established for friction stir welding (FSW) processes of engineering alloys. The commonly assumed sintering-like diffusional-bonding hypothesis is criticized in this work as not the dominant mechanism. For the wide spectrum of material constitutive laws and FSW processing conditions examined and employed in realistic applications, the thermomechanical history on the workpiece–workpiece interface traverses in the creep-dominated regime for the growth/shrinkage of interfacial cavities. The evolution of the bonding fraction relies mainly on the creep strain rate in the adjourning workpieces, weakly on stress triaxiality, and negligibly on interfacial diffusion.

36 MATERIALS SCIENCE↗

Techno-economic analysis of cathode material production using flame-assisted spray pyrolysis

The cost of cathode materials contributes approximately 32.7% of the total cell construction cost of lithium-ion batteries, significantly affecting the price of battery packs. To reduce the cathode material manufacturing cost, a flame-assisted spray pyrolysis (FSP) method has been developed to utilize a sustainable solvent of glycerol to manufacture the LiNi 1/3 Mn 1/3 Co 1/3 O 2 (NMC333) cathode materials. The purpose of this study is to evaluate the minimum cathode material selling price (MCSP) of the FSP processes compared with a traditional carbonate co-precipitation pathway. Results show that the MCSP of the FSP is $\$$19.1/kg that is 17% lower than the traditional carbonate co-precipitation pathway as a result of lower fixed operating cost and variable overhead. Sensitivity analysis shows that when the new process is integrated with in-situ sintering and processing, the MCSP can be as low as $\$$15.6/kg. When all the material prices are decreased by 20%, the FSP process can synthesize NMC333 at a price of $\$$2.3/kg lower. According to the simulation result, LiNi 0·8 Mn 0·1 Co 0·1 O 2 (NMC811) has the best potential to meet the U.S. Department of Energy battery price target of $\$$125/kWh, demonstrating that the FSP process is an attractive manufacturing technology for NMC cathode powder material production.

25 ENERGY STORAGE↗

Multi-scale stabilization of high-voltage LiCoO 2 enabled by nanoscale solid electrolyte coating

LiCoO 2 (LCO) possess a high theoretical specific capacity of 274 mAh g -1 , and currently LCO charged to 4.48 V with a capacity of ~190–195 mAh g -1 is penetrating the commercial markets. Scalable strategies to further enhance the performance of LCO are highly attractive. Here, we develop a scalable ball-milling and sintering method to tackle this long-standing challenge by modifying LCO surface with only 1.5–3.5% ceramic solid electrolyte nanoparticles, specifically Li 1.5 Al 0.5 Ge 1.5 (PO 4 ) 3 (LAGP) as an example. Consequently, the atomic-to-meso multiscale structural stabilities have been significantly improved, even with a high cut-off voltage of 4.5 V vs. Li/Li + , leading to excellent electrochemical stabilities. The nano-LAGP modified Li|LCO cell exhibits high discharge capacity of 196 mAh g -1 at 0.1 C, capacity retention of 88% over 400 cycles, and remarkably enhanced rate capability (163 mAh g -1 at 6 C). These results show significant improvement compared to the Li|LCO cells. The as-prepared graphite|LAGP-LCO full cells also show steady cycling with 80.4% capacity retention after 200 cycles with a voltage cut-off of 4.45 V. This work provides a simple and scalable approach to achieve stable cycling of LCO at high voltage with high energy density.

25 ENERGY STORAGE↗

Self-Stabilized LiNi 0.8 Mn 0.1 Co 0.1 O 2 in thiophosphate-based all-solid-state batteries through extra LiOH

Nickle-rich LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NMC 811) cathode material exhibits engaging properties in high energy density and low cost, making it great potential for the next generation high-energy all-solid-state lithium batteries (ASSLBs). However, NMC 811 suffers from severe surface electrochemical, chemical, and voltage incompatibility towards solid-state electrolytes (SSE), especially thiophosphate-based electrolytes like Li 6 PS 5 Cl. Although diverse coating methods have been made to overcome this issue, they are typically cumbersome and expensive. A coating strategy that satisfied all the requirements of cost-efficiency, stability, uniformity, scalability, and easy-achieving is still challenging. Here, we developed a LiOH-based surface stabilization strategy that provides a ~10 nm stable permeable layer on NMC 811. After one-step sintering of NMC 811 precursor mixed with LiOH, which is commonly used for NMC 811 lithiation process, excessive LiOH simultaneously distributes on NMC 811 particles. Unlike other reported methods, this coating method can be easily controlled and fabricated without additional complicated processes. By simply controlling the thickness of LiOH layer, which protects the Li 6 PS 5 Cl solid electrolyte materials from being oxidized, optimized cycling stability can be obtained for 600 cycles with capacity of 130 mAh g – 1 on average at a wide electrochemical window of 2.50–4.20 V (vs. Li-In).

25 ENERGY STORAGE↗