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All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Efficacy of a Solution-Based Approach for Making Sodalite Waste Forms for an Oxide Reduction Salt Utilized in the Reprocessing of Used Uranium Oxide Fuel

This paper describes various approaches for making sodalite with a LiCl-Li2O oxide reduction salt used to recover uranium from used oxide fuel. The approaches include sol-gel and solution-based synthesis processes. As-made products were mixed with 5 and 10 mass% of a Na2O-B2O3-SiO2 glass binder and these, along with product without a binder, were heated using either a cold-press-and-sinter method or hot uniaxial pressing. The results demonstrate the limitation of sodalite yield due to the fast intermediate reactions between Na+ and Cl- to form halite in solution and Li2O and SiO2 to form lithium silicates (e.g., Li2SiO3 or Li2Si2O5) in the calcined and sintered pellets. The results show that pellets can be made with high sodalite fractions (~92 mass%) and low porosities using a solution-based approach and this LiCl-Li2O salt.

electrochemical↗
DOE OSTI2017

Irradiation resistance of silicon carbide joint at light water reactor–relevant temperature

We fabricated and irradiated monolithic silicon carbide (SiC) to SiC plate joints with neutrons at 270–310 °C to 8.7 dpa for SiC. The joining methods included solid state diffusion bonding using titanium and molybdenum interlayers, SiC nanopowder sintering, reaction sintering with a Ti-Si-C system, and hybrid processing of polymer pyrolysis and chemical vapor infiltration (CVI). All the irradiated joints exhibited apparent shear strength of more than 84 MPa on average. Significant irradiation-induced cracking was found in the bonding layers of the Ti and Mo diffusion bonds and Ti-Si-C reaction sintered bond. Furthermore, the SiC-based bonding layers of the SiC nanopowder sintered and hybrid polymer pyrolysis and CVI joints all showed stable microstructure following the irradiation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2015

Preparation of LTCC materials with adjustable permittivity based on BaO–B{sub 2}O{sub 3}–SiO{sub 2}/BaTiO{sub 3} system

Graphical abstract: The dielectric constant (ϵ) of the sintered BaO–B{sub 2}O{sub 3}–SiO{sub 2}/BaTiO{sub 3} glass/ceramics (the sintered samples with line shrinkage of 10%) changed from 5 to 30 and the dielectric losses (tanδ) was lower than 0.05 at 100 MHz with the amount of BaTiO{sub 3} additive increment from 60 wt% to 90 wt% fraction. - Highlights: • The ϵ of BaO–B{sub 2}O{sub 3}–SiO{sub 2} glass can be adjusted from 5 to 30 by adding BaTiO{sub 3}. • The influence factors on dielectric are the secondary phase and microstructure. • BaO–B{sub 2}O{sub 3}–SiO{sub 2}/BaTiO{sub 3} system can fabricate LTCC when BaTiO{sub 3} located in 60–80 wt%. - Abstract: This paper studied the preparation and characterization of LTCC (low temperature co-fired ceramics) materials based on BaO–B{sub 2}O{sub 3}–SiO{sub 2}/BaTiO{sub 3} glass–ceramics, where the sintering temperature was about 900 °C and dielectric constant was effectively adjustable from 5 to 30 by changing the BaTiO{sub 3} fraction from 60 wt% to 90 wt%. X-ray diffractometer (XRD), scanning electron microscopy (SEM) were used to examine the effect of different amounts additive on the dielectric properties of this LTCC system and the crystal structure change. The results indicated that BaTiO{sub 3} can be used as a dielectric additive aim to adjust the permittivity of BaO–B{sub 2}O{sub 3}–SiO{sub 2} glass, which the main influence factors on dielectric are the contents of the secondary phase, the BaTiO{sub 3} phase fraction and the porous structure of the sintered body. Therefore, the microstructure and dielectric property of BaO–B{sub 2}O{sub 3}–SiO{sub 2}/BaTiO{sub 3} glass–ceramics composites could be controlled by adjusting the content of BaTiO{sub 3} additive.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Exploring the structural uniformity and integrity of protonic ceramic thin film electrolyte using wet powder spraying

Thin protonic ceramic electrolyte contributes to lower ohmic resistance and enhances electrochemical performance of protonic ceramic electrochemical cells. However, manufacturing of large-scale thin electrolyte remains a challenge. Wet powder spraying is an attractive technique to deposit <10 µm thin electrolyte when advanced atomizing techniques and optimized spraying process are integrated. Here ultrasonic atomization is integrated in the wet powder spray technique to reduce the thickness of electrolyte. Moreover, a parametric study is conducted to optimize the wet powder spray process to deposit uniform and crack-free electrolyte film. It is illustrated that tuning of solid loading rates and spray passes can affect the morphology of the as-sprayed electrolyte film, enabling the structural compactness of the sintered electrolyte layer. To maintain chemical stability of the electrolyte layer during sintering, effect of sintering temperature is further investigated to produce a physically thin, structurally dense, and chemically homogeneous electrolyte layer. The protonic ceramic electrochemical cells fabricated with optimized spraying and sintering parameters demonstrate excellent performance under both fuel cell and electrolysis modes. In addition, the cells exhibit remarkable structural integrity during redox and long-term stability tests.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Three-dimensional hierarchical nanoporous copper via direct ink writing and dealloying

Three-dimensional (3D) hierarchical nanoporous Cu (3DHNP-Cu) is synthesized using a combination of direct ink writing (DIW) based 3D printing, thermal sintering, and chemical dealloying of Mn–Cu alloys. Through tuning processing conditions such as ink composition and cooling rate (after sintering), with consideration of Mn loss during sintering, 3DHNP-Cu with fully bicontinuous nanostructures and negligible residual Mn can be produced after dealloying. The 3DHNP-Cu is comprised of structural features that span seven orders of magnitude, where DIW digitally controls macroscale porous features, thermal sintering and degradation of the binding polymer determines microscale porous features, and dealloying gives rise to nanoscale pores.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Ceria nanoclusters on graphene/Ru(0001): A new model catalyst system

The growth of ceria nanoclusters on single-layer graphene on Ru(0001) has been examined, with a view towards fabricating a stable system for model catalysis studies. The surface morphology and cluster distribution as a function of oxide coverage and substrate temperature has been monitored by scanning tunneling microscopy (STM), whereas the chemical composition of the cluster deposits has been determined by Auger electron spectroscopy (AES). The ceria nanoparticles are of the CeO2(111)-type and are anchored at the intrinsic defects of the graphene surface, resulting in a variation of the cluster densities across the macroscopic sample surface. The ceria clusters on graphene display a remarkable stability against reduction in ultrahigh vacuum up to 900 K, but some sintering of clusters is observed for temperatures >450 K. The evolution of the cluster size distribution suggests that the sintering proceeds via a Smoluchowski ripening mechanism, i.e. diffusion and aggregation of entire clusters.

Ceria, CeO2, nanoclusters, graphene, Ru(0001), Smo↗
DOE OSTI2022

Templated encapsulation of platinum-based catalysts promotes high-temperature stability to 1,100 °C

Stable catalysts are essential to address energy and environmental challenges, especially for applications in harsh environments (for example, high temperature, oxidizing atmosphere and steam). In such conditions, supported metal catalysts deactivate due to sintering-a process where initially small nanoparticles grow into larger ones with reduced active surface area-but strategies to stabilize them can lead to decreased performance. In this work, we report stable catalysts prepared through the encapsulation of platinum nanoparticles inside an alumina framework, which was formed by depositing an alumina precursor within a separately prepared porous organic framework impregnated with platinum nanoparticles. These catalysts do not sinter at 800 °C in the presence of oxygen and steam, conditions in which conventional catalysts sinter to a large extent, while showing similar reaction rates. Extending this approach to Pd-Pt bimetallic catalysts led to the small particle size being maintained at temperatures as high as 1,100 °C in air and 10% steam. This strategy can be broadly applied to other metal and metal oxides for applications where sintering is a major cause of material deactivation.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Welding of Semiconductor Nanowires by Coupling Laser-Induced Peening and Localized Heating

We demonstrate that laser peening coupled with sintering of CdTe nanowire films substantially enhances film quality and charge transfer while largely maintaining basic particle morphology. During the laser peening phase, a shockwave is used to compress the film. Laser sintering comprises the second step, where a nanosecond pulse laser beam welds the nanowires. Microstructure, morphology, material content and electrical conductivities of the films are characterized before and after treatment. The morphology results show that laser peening can decrease porosity and bring nanowires into contact and pulsed laser heating fuses those contacts. Multiphysics simulations coupling electromagnetic and heat transfer modules demonstrate that during pulsed laser heating, local EM field enhancement is generated specifically around the contact areas between two semiconductor nanowires, indicating localized heating. The characterization results indicate that solely laser peening or sintering can only moderately improve the thin film quality; however, when coupled together as laser peen sintering (LPS), the electrical conductivity enhancement is dramatic. LPS can decrease resistivity up to a factor of ~10,000, resulting in values on the order of ~10 5 Ω-cm in some cases, which is comparable to CdTe thin films. Our work demonstrates that LPS is an effective processing method to obtain high-quality semiconductor nanocrystal films.

Science & Technology - Other Topics↗
DOE OSTI2015

Robust Ag nanoplate ink for flexible electronics packaging

Nanoinks are currently a topic of heightened interest with respect to low temperature bonding processes and printable electronics. We have developed an innovative polyvinylpyrrolidone (PVP)-stabilized Ag nanoplate ink amenable to very strong low temperature packaging, and investigated the relationship between bonding strength and electrical conductivity post-bonding. PVP shell plastic deformations observed in failure microcracks with the formation of PVP nanofibers, revealed bonding strength at low temperatures (<250 °C) was primarily due to adhesive bonding. Here, it is found that, utilizing photonic sintering, ~70 °C reduction of transformation temperature from adhesive to metallic bonding was achieved compared to that of thermal sintering. A numerical simulation was developed to better understand the influences of the light-induced heat generation, which demonstrated near-infrared light can facilitate sintering. Bonding strengths of 27 MPa were achieved at room temperatures, and 29.4 MPa at 210 °C with photonic sintering. Moreover, the anisotropic resistivity was observed with different thermal dependences. Furthermore, these results demonstrate Ag nanoplate inks have potential for low temperature 3D interconnections in lead-free microcircuits, flexible electronic packaging, and diverse sensing applications.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2013

Studying some mechanical properties of MgO with used neon bulb glass

Ceramic compact of MgO +WT% of UNBG were sintered at different sintering temperature (700, 900, 1100, 1300)°c, under static air for 3 hours. X-ray diffraction and some mechanical properties were conducted. The maximum sintered density, compression; fracture strength and hardness were indicated for the compilation of MgO −20 WT % UNBG, sintered at 1300 °c.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Effect of CNTs dispersion on the thermal and mechanical properties of Cu/CNTs nanocomposites

Modified technique of metal injection molding (MIM) was used to fabricate multiwalled carbon nanotube (CNT) reinforced Cu nanocomposites. The effect of adding different amount of CNTs (0-10 vol.%) on the thermal and mechanical behaviour of the fabricated nanocomposites is presented. Scanning electron microscope analysis revealed homogenous dispersion of CNTs in Cu matrices at different CNTs contents. The experimentally measured thermal conductivities of Cu/CNTs nanocomposites showed extraordinary increase (76% higher than pure sintered Cu) with addition of 10 vol.% CNTs. As compared to the pure sintered Cu, increase in modulus of elasticity (Young's modulus) of Cu/CNTs nanocomposites sintered at 1050°C for 2.5 h was measured to be 48%. However, in case of 7.5 vol.% CNTs, Young's modulus was increased significantly about 51% compared to that of pure sintered Cu.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Mechanical and electrical properties of low temperature phase MnBi

Low temperature phase (LTP) manganese bismuth (MnBi) is a promising rare-earth-free permanent magnet material due to its high intrinsic coercivity and large positive temperature coefficient. While scientists are making progress on fabricating bulk MnBi magnets, engineers have begun considering MnBi magnets for motor applications. Physical properties other than magnetic ones could significantly affect motor design. Here, we report results of our investigation on the mechanical and electrical properties of bulk LTP MnBi and their temperature dependence. A MnBi ingot was prepared using an arc melting technique and subsequently underwent grinding, sieving, heat treatment, and cryomilling. The resultant powders with a particle size of ∼5 μm were magnetically aligned, cold pressed, and sintered at a predefined temperature. Micro-hardness testing was performed on a part of original ingot and we found that the hardness of MnBi was 109 ± 15 HV. The sintered magnets were subjected to compressive testing at different temperatures and it was observed that a sintered MnBi magnet fractured when the compressive stress exceeded 193 MPa at room temperature. Impedance spectra were obtained using electrochemical impedance spectroscopy at various temperatures and we found that the electrical resistance of MnBi at room temperature was about 6.85 μΩ m.

Jiang, Xiujuan↗
DOE OSTI2016

Microstructure evolution and electrical characterization of Lanthanum doped Barium Titanate (BaTiO{sub 3}) ceramics

In the current work, we investigated the structural and dielectric properties of Lanthanum oxide (La{sub 2}O{sub 3}) doped Barium Titanate (BaTiO{sub 3}) ceramics and established a correlation between them. Solid state sintering method was used to dope BaTiO{sub 3} with 0.3, 0.5 and 0.7 mole% La{sub 2}O{sub 3} under different sintering parameters. The raw materials used were La{sub 2}O{sub 3} nano powder of ~80 nm grain size and 99.995% purity and BaTiO{sub 3} nano powder of 100 nm grain size and 99.99% purity. Grain size distribution and morphology of fracture surface of sintered pellets were examined by Field Emission Scanning Electron Microscope and X-Ray Diffraction analysis was conducted to confirm the formation of desired crystal structure. The research result reveal that grain size and electrical properties of BaTiO{sub 3} ceramic significantly enhanced for small amount of doping (up to 0.5 mole% La{sub 2}O{sub 3}) and then decreased with increasing doping concentration. Desired grain growth (0.80-1.3 µm) and high densification (<90% theoretical density) were found by proper combination of temperature, sintering parameters and doping concentration. We found the resultant stable value of dielectric constant was 10000-12000 at 100-300 Hz in the temperature range of 30°-50° C for 0.5 mole% La{sub 2}O{sub 3} with corresponding shift of curie temperature around 30° C. So overall this research showed that proper La{sup 3+} concentration can control the grain size, increase density, lower curie temperature and hence significantly improve the electrical properties of BaTiO{sub 3} ceramics.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

A rational asymmetric hollow fiber membrane for oxygen permeation

Abstract A typical oxygen permeation hollow fiber membrane fabricated by phase inversion‐based extrusion process demonstrates heterogeneous porous microstructures, in which the surface layer with relatively low porosity is used as a separation layer after sintering. It is usually not convenient to control the thickness of separation layer. And a high sintering temperature is needed to densify the separation layer, which in turn could destroy the desired porous microstructures in other portion. This paper studies a novel process to fabricate multilayer asymmetric hollow fiber membrane with a rational design using 67 vol. % Gd 0.2 Ce 0.8 O 2−δ −33 vol. % La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3−δ ( GDC ‐ LSCF ) as a model material system. The phase inversion‐based extrusion process in open literature is employed to fabricate a hollow fiber substrate featuring radially well‐aligned microchannels open at the inner surface. Built upon the hollow fiber substrate, a thin dense separation layer and porous surface catalyst layer at shell side are then fabricated through dip‐coating and sintering process alternatively. The oxygen permeation flux of the fabricated hollow fiber membrane reaches 2.68 mL/cm 2 /min at 900°C under Ar/air gradient, the highest performance of the membranes with GDC ‐ LSCF material system in open literature. The innovative fabrication process is able to readily control the thickness of functional layers while decreasing sintering temperatures.

Ren, Chunlei↗
DOE OSTI2020

Thermal, mechanical, and electrical properties of LSCo/mullite composite contact materials for solid oxide fuel cells

Lanthanum strontium cobaltite (LSCo) is considered as a good candidate cathode contact material for solid oxide fuel cells, due to high electrical conductivity. However, LSCo has a very large coefficient of thermal expansion (CTE) than the cells and metallic interconnects. As a result, poor mechanical stability is expected during thermal cycling. To minimize the CTE mismatch, we investigate a composite approach involving mixing LSCo with an inert material of low CTE, such as mullite at volume fractions from 0.1 to 0.4. Composite’s CTE shows a decreasing trend with increasing mullite volume fractions, and is consistent with model predictions. X-ray powder diffraction analysis of sintered LSCo/mullite composites exhibits no presence of other phases for samples aged for 500h at 800oC, indicating chemical compatibility. Electrical conductivity by a 4-pt method shows a decreasing trend with increasing mullite content. Contact strength of as-sintered and thermally cycled samples show that only the composite with 0.4 volume fraction has a measurable strength; the other composites have no strength. Overall, the composite approach is demonstrated in the LSCo/mullite system to lower the CTE and hence achieve thermal cycle stability. The addition of the inert phase to the LSCo matrix; however, also reduces the electrical conductivity.

Contact materials, LSCo, mullite, CTE, electrical ↗
DOE OSTI2022

Mass Transport in Binary TiO 2 :SiO 2 and GeO 2 :SiO 2 Direct Ink Write Glasses

The mass transport mechanisms of Ti in TiO 2 :SiO 2 and Ge in GeO 2 :SiO 2 direct ink write, additively manufactured glasses were studied. Due to the low solubility of Ti in SiO2 and high melting point of TiO 2 relative to SiO 2 , Ti transport was found to occur via solid state interdiffusion between adjoining SiO 2 and TiO 2 precursor particles. The diffusivity of titanium in SiO 2 measured over typical sintering temperatures (1000-1300 °C) using Rutherford backscattering spectrometry was D = 9.1 × 10 -7 [m2/sec] exp ($\frac{378[\frac{kJ}{mol}]}{RT}$. This provides an estimate of ~30 nm for the diffusion length under typical sintering conditions (2 hrs. at 1200 °C). Although Ti and Ge have similar diffusivities in SiO 2 glass at low concentrations, GeO 2 was found to be much more mobile during the sintering of printed GeO 2 :SiO 2 green bodies. This was evident in glasses with phase separated GeO 2 regions over length scales of ~10 μm and in experiments involving binary xerogels in which GeO 2 migrated over ~10 μm through cracked, porous SiO 2 layers. Large phase separated regions and long transport lengths in GeO 2 :SiO 2 suggest that the transport of GeO 2 occurs prior to the densification of the SiO 2 matrix via an alternative mechanism such as capillary flow. These results inform important considerations in the design of index modifying inks for the direct ink write process, namely initial precursor phase, mutual solubility with the base SiO 2 glass, and mass transport throughout the sintering process.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Structural Reliability of Cathode Contact Materials in Planar SOFCs

Despite significant developments in material and stack design technologies to enhance performance, the long-term mechanical reliability of solid oxide fuel cells remained an issue. The contact between electrodes and interconnects (especially the cathode side) was identified as one of the weakest links in present generation planar solid oxide fuel cells. Computational modeling was used to gain valuable insights on the cathode contact sintering mechanics and bond reliability. A continuum viscous sintering model was incorporated into a commercial finite element analysis code to simulate contact material densification and evaluate the bond and stack mechanical reliability due to developed stresses from the contact layer sintering. The parameters required for the cathode contact material constitutive model were extracted from experiments conducted for the contact material development at PNNL. The effects of contact layer thickness and sintering conditions like temperature and pressure on the stack stresses and reliability were investigated.

SOFC, FEA, Reliability↗
DOE OSTI2021

Temperature-Swing Synthesis of Large-Size Single-Crystal LiNi 0.6 Mn 0.2 Co 0.2 O 2 Cathode Materials

Single-crystal lithium-nickel-manganese-cobalt-oxide (SC-NMC) has recently emerged as a promising battery cathode material due to its outstanding cycle performance and mechanical stability over the tradional polycrystalline NMC. It is favorable to further increase the grain size of SC-NMC particles to achieve a higher volumetric energy density and minimize surface-related degradations. However, the preparation of large-size yet high performance SC-NMC particles faces a challenge in choosing a suitable temperature for sintering. High temperature promotes grain growth but induces cation mixing that negatively impacts the electrochemical performance. Here we report a temperature-swing sintering (TSS) strategy with two isothermal stages that fulfils the needs for grain growth and structural ordering sequentially. A high-temperature sintering is first used for a short period of time to increase grain size and then the reaction temperature is lowered and kept constant for a longer period of time to improve structural ordering and complete the lithiation process. SC-LiNi 0.6 Mn 0.2 Co 0.2 O 2 materials prepared via TSS exhibit large grain size (~4 μm), a low degree of cation mixing (~0.9%), and outperform the control samples prepared by the conventional sintering method. Furthermore, this work highlights the importance of understanding the process-structure-property relationships and may guide the synthesis of other SC Ni-rich cathode materials.

25 ENERGY STORAGE↗