Method of Preparing a Solid Oxide Fuel Cell

A solid oxide fuel cell having a multichannel electrode architecture and method for preparing the same, the method including forming a first carbon laden composition, including a first thermoplastic binder, into a rod, applying a first zirconia laden composition, including a second thermoplastic binder, onto the rod to form a composite feed rod, extruding the composite feed rod to form a controlled geometry filament, bundling the extruded composite feed rod to form a multicellular feed rod, extruding the multicellular feed rod to form a multicellular rod, cutting the multicellular rod into multicellular discs, applying a zirconia laden material to one surface of a multicellular discs to form a multicellular structure, and heating processing the multicellular structure. The fuel cell is completed by adding anode and cathode materials to the multicellular structure

Densification of Ultra-Refractory Transition Metal Diboride Ceramics

The densification behavior of transition metal diboride compounds was reviewed with emphasis on ZrB2 and HfB2. These compounds are considered ultra-high temperature ceramics because they have melting temperatures above 3000°C. Densification of transition metal diborides is difficult due to their strong covalent bonding, which results in extremely high melting temperatures and low self-diffusion coefficients. In addition, oxide impurities present on the surface of powder particles promotes coarsening, which further inhibits densification. Studies prior to the 1990s predominantly used hot pressing for densification. Those reports revealed densification mechanisms and identified that oxygen impurity contents below about 0.5 wt% were required for effective densification. Subsequent studies have employed advanced sintering methods such as spark plasma sintering and reactive hot pressing to produce materials with nearly full density and higher metallic purity. Further studies are needed to identify fundamental densification mechanisms and further improve the elevated temperature properties of transition metal diborides

Synthesis, densification, and properties of high entropy ultra-high temperature ceramics

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Reaction Sintered Zirconium Carbide/Tungsten Composite Bodies and a Method for Producing the Same

A method of sintering a composite body characterized by a transition metal carbide phase (such as a ZrC phase) substantially evenly distributed in a second, typically refractory, transition metal (such as W) matrix at ambient pressures, including blending a first predetermined amount of first transition metal oxide powder (such as ZrO2) with a second predetermined amount of second transition metal carbide powder (such as WC powder). Next the blended powders are mixed to yield a substantially homogeneous powder mixture and a portion of the substantially homogeneous powder mixture is formed into a green body. The body is fired to a first temperature, wherein the first transition metal oxide is substantially reduced and the simultaneously generated CO and gas are evolved from the body to substantially eliminate oxides from the green body, and the body is heated to a second temperature and sintered to yield a composite body of about 99 percent theoretical density and characterized by a first transition metal carbide phase distributed substantially evenly in a second transition metal matrix

Method for Producing Pressurelessly Sintered Zirconium Diboride/Silicon Carbide Composite Bodies

A method of sintering a ZrB2-SiC composite body at ambient pressures, including blending a first predetermined amount of ZrB2 powder with a second predetermined amount of SiC powder, wherein both powders are characterized by the presence of surface oxide impurities. Next the blended powders are mixed to yield a substantially homogeneous powder mixture and a portion of the substantially homogeneous powder mixture is formed into a green body. The body is fired to a first temperature, wherein substantially all surface oxide impurities are reduced and/or volatilized to substantially eliminate oxides from the green body, and the body is heated to a second temperature and sintered to yield a composite body of at least about 99 percent theoretical density and characterized by SiC whisker-like inclusions distributed substantially evenly in a ZrB2 matrix

Mechanical andthermal properties of Zeta phase tantalum carbide atelevated temperatures

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Mechanical properties of borothermally synthesized ZrB2

Mechanical properties of borothermally synthesized, highly pure ZrB2 were tested at room and elevated temperatures. Commercially available ZrB2 powder typically contains 1 to 4 wt % hafnium which has been shown to lower thermal properties of dense ZrB2 ceramics. Further, commercial grade ZrB2 contains other impurities (0.6 wt% O, 0.11 wt% N, 0.04 wt% Fe and others) which are also known to decrease its high-temperature mechanical strength. Purer grades of zirconia and boron powders, containing \u3c 75 ppm hafnium and \u3c0.5 wt% of other metal impurities, were reacted to produce ZrB2 for room and elevated temperature mechanical property studies. The zirconia and boron powders were reacted at 1000°C in a graphite vacuum furnace for two hours. The synthesized ZrB2 powder was then rinsed with methanol to remove boria from its surfaces, sieved with a #45 mesh, and hot pressed to near full density with 32 MPa applied pressure in a flowing argon atmosphere at 2100°C. The hot pressed billets were machined to ASTM standard test bars with the flexure surface polished to 1 um. Young’s modulus, Vickers Hardness, fracture toughness, and four-point bend strength were measured, and the results will be discussed

Effects of transition metals on thermal properties of ZrB2

Nominally phase pure zirconium diboride ceramics were synthesized to study their intrinsic thermal properties. Ceramics for this study were synthesized by reaction hot pressing of reactor grade ZrH2 and B to minimize impurities commonly found in commercial powders such as the natural abundance (1-4 wt%) of Hf. Starting powders contained \u3c200 ppm Hf. Previous results showed that Hf impurities present in quantities comparable to commercial powders masked the effect of other transition metal additions. For example, additions of 3 at% Ti and Y had no apparent effect on thermal conductivity of ceramics produced from commercial ZrB2. Lowering the Hf content to 0.4 at% increased thermal conductivity from ~90 W/m•K for ZrB2 ceramics prepared from commercial powders to ~100 W/m•K for low-Hf content ZrB2 at 25 °C. Lowering the Hf content also increased the thermal conductivity at 2000°C from ~70 W/m•K to ~80 W/m•K. For the low Hf ZrB2, adding 3 at% TiB2 decreased thermal conductivity ~15 W/m•K at 25°C while adding 3 at% MoB2 decreased thermal conductivity ~45 W/m•K at 25°C. For the present study, transition metals such as Hf, Ti, Y, Ta, and W were added individually to nominally phase pure ZrB2 to study the effects on thermal diffusivity, thermal conductivity and heat capacity at temperatures from 25°C to 2000°C. These properties will be compared to values obtained for ceramics prepared from commercial ZrB2 powders, which contained the natural abundance of Hf. Most previous reports have relied on heat capacity values from the NIST-JANAF thermodynamic tables to calculate thermal conductivity of ZrB2 ceramics. However, the heat capacity of ZrB2 with low Hf content was approximately 10% greater than widely accepted values. Due to this difference, heat capacity will be measured for each composition, and these values will be used to calculate thermal conductivity. The intrinsic thermal properties of ZrB2will be discussed as well as the effect of transition metal additions on the thermal properties of ZrB2 with low and naturally abundant quantities of Hf