Durable, Impermeable Brazes for Solid Oxide Fuel Cells (Final Report)
To develop a new braze to replace the current state-of-the-art Ag-CuO reactive air braze (RAB), two approaches were proposed: 1) development of a new, self-passivating, silver-free braze and 2) development of a CuO-free, silver-based braze. For the first approach, an integrated computational-experimental method was used. Thermo-Calc® was utilized to quickly screen through hundreds of alloy systems to identify candidate braze compositions with the appropriate melting ranges. Material compositions, melting ranges, mechanical properties, oxidation resistance, and wetting characteristics of the candidate alloys were then analyzed experimentally. Substrate surface pre-treatments, active element additions, and novel brazing schemes were also investigated. Unfortunately, the current study failed to identify new silver-free braze compositions suitable for SOFC applications. To help measure the passivation characteristics of surface passivating braze oxide coatings, work was conducted to demonstrate, for the first time, that a variety of disparate and technologically-relevant thermal, mechanical, and electrochemical oxygen-exchange thin film material properties could all be obtained from in situ , current-collector-free wafer curvature measurements. Specifically, temperature or oxygen partial pressure induced changes in the curvature of 230 nm thick (100)-oriented Pr 0.1 Ce 0.9 O 1.95_x (10PCO) films atop 200 mm thick single crystal yttria stabilized zirconia or magnesium oxide substrates were used to measure the biaxial modulus, Young’s modulus, thermal expansion coefficient, thermochemical expansion coefficient, oxygen nonstoichiometry, chemical oxygen surface exchange coefficient, oxygen surface exchange resistance, thermal stress, chemical stress, thermal strain, and chemical strain of the model mixed ionic electronic conducting material 10PCO. The (100)-oriented thin film 10PCO thermal expansion coefficient, thermo-chemical expansion coefficient, oxygen nonstoichiometry, and Young’s modulus (which is essentially constant, at ~200 MPa, over the entire 280–700 °C temperature range in air) measured here were similar to those from other bulk and thin film 10PCO studies. In addition, the measured PCO10 oxygen surface coefficients were in agreement with those reported by other in situ , current collector- free techniques. However, the measured PCO10 oxygen surface exchange coefficients were significantly lower than those obtained from literature studies with large amounts of intentional or inadvertent precious metal surface coverage/contamination (suggesting that uncontaminated (100)-oriented 10PCO may not be a desirable SOFC cathode material). Taken together, this highlighted the advantages of using a sample’s mechanical response, instead of the more traditional electrical response, to probe the electrochemical properties of the ion-exchange materials used in solid oxide fuel cell, solid oxide electrolysis cell, gas-sensing, battery, emission control, water splitting, water purification, and other electrochemically-active devices. For the second approach, a novel silver-nickel brazing method was developed. It was demonstrated that transient porous nickel interlayers, instead of reactive element additions, could be used to promote Ag wetting on yttria stabilized zirconia (YSZ) and produce high-quality YSZ stainless steel (SS) braze joints. Mechanical tests on these reactive-element-free, silver-based SOFC braze joints, both before and after 500 hours of 750°C oxidation in air, showed that the braze and braze interface strength were higher than the underlying YSZ|NiO-YSZ substrate. The microstructural and compositional evolution of SS|Ag-Ni|YSZ braze joints exposed to dual atmosphere (air on one side and 4%H 2 -96%N 2 on the other side) for 300 hours of isothermal 750 °C aging and 300 25°C/min 35-830 °C rapid thermal cycles were compared to a Ag-3CuO braze joint. In contrast to conventional Ag-CuO RAB brazes, the Ag-Ni brazes remained pore free and well bonded, suggesting that Ag-Ni brazes may be more suitable for long term SOFC operation than Ag-CuO brazes. Other applications inspired by the silver-nickel wetting process on various ceramic substrates were also explored. In support of efforts to identify new CuO-free Ag-based brazes, density functional theory and ab initio molecular dynamics calculations were performed to 1) understand silver wetting on YSZ, and 2) identify new oxides to promote silver wetting on YSZ. These simulations found that while the formation of dissolved oxygen clusters within molten silver at the YSZ interface promoted wetting, much greater wetting angle reductions came from the formation of metal oxide interlayers at the Ag-YSZ interface. Through the development of a simple descriptor, many simple metal oxides (single cation) were examined. Unfortunately, their ability to promote Ag wetting were less than that of CuO. However, expanding the search to multi-cation oxides led to several promising candidates, such as CuAlO 2 , CuGaO 2 , and Cu 3 TiO 4 ; all of which are also stable in the reducing SOFC conditions. Depending upon their solubility in molten Ag, these newly-identified oxides could either be pre-applied as wetting promoting interlayers or directly incorporated into Ag to form new reactive air brazes.