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Direct Microwave Sintering of Poorly Coupled Ceramics in Electrochemical Devices
Amiri, Taghi,Etsell, Thomas H.,Sarkar, Partha The Korean Electrochemical Society 2022 Journal of electrochemical science and technology Vol.13 No.3
The use of microwaves as the energy source for synthesis and sintering of ceramics offers substantial advantages compared to conventional gas-fired and electric resistance furnaces. Benefits include much shorter processing times and reaching the sintering temperature more quickly, resulting in superior final product quality. Most oxide ceramics poorly interact with microwave irradiation at low temperatures; thus, a more complex setup including a susceptor is needed, which makes the whole process very complicated. This investigation pursued a new approach, which enabled us to use microwave irradiation directly in poorly coupled oxides. In many solid-state electrochemical devices, the support is either metal or can be reduced to metal. Metal powders in the support can act as an internal susceptor and heat the entire cell. Then sufficient interaction of microwave irradiation and ceramic material can occur as the sample temperature increases. This microwave heating and exothermic reaction of oxidation of the support can sinter the ceramic very efficiently without any external susceptor. In this study, yttria stabilized zirconia (YSZ) and a Ni-YSZ cermet support were used as an example. The cermet was used as the support, and a YSZ electrolyte was coated and sintered directly using microwave irradiation without the use of any susceptor. The results were compared to a similar cell prepared using a conventional electric furnace. The leakage test and full cell power measurement results revealed a fully leak-free electrolyte. Scanning electron microscopy and density measurements show that microwave sintered samples have lower open porosity in the electrode support than conventional heat treatment. This technique offers an efficient way to directly use microwave irradiation to sinter thin film ceramics without a susceptor.
Fabrication of thin porous electrolyte-supported tubular fuel cells using slip casting
Amir Reza Hanifi,Alireza Torabi,Alyssa Shinbine,Thomas H. Etsell,Partha Sarkar 한양대학교 세라믹연구소 2011 Journal of Ceramic Processing Research Vol.12 No.3
In the current research the third generation of tubular solid oxide fuel cells (SOFCs) which is believed to solve the redox cycling problem is introduced and the cell configuration is discussed. This type of ceramic fuel cell consists of a slip cast porous support of approximately 500 μm thickness coated with a thin dense electrolyte layer both made of calcined YSZ. The porous support can have up to 50% porosity as a result of both the preliminary calcination of YSZ powder and the addition of a pore former. Different parameters that affect the porosity content and thickness of the supports are also studied. It is shown that the short casting time required for high porosity tubes can be controlled by modifying the solid loading of the slip and/or the porosity of the plaster mold. Finally, multiple casting is introduced as a coating method in which the electrolyte layer with the required thickness can be slip cast directly onto the porous support.