Battelle Memorial Institute

Ut-battelle, Inc.

Jeffry W Stevenson

Yeong-Shyung Matt Chou

Kerry D Meinhardt

Wayne A Surdoval

Olga A Marina

Vincent L Sprenkle

Joseph Thomas Muth

Zhenguo Yang

Beth Louise Armstrong

Edgar Lara-Curzio

Amit Shyam

Nathan L Canfield

Jung-Pyung Choi

Yanli Wang

Guan-Guang Xia

Mohammad A Khaleel

Travis Shultz

Elizabeth V Stephens

Xin Sun

Wenning Liu

Rosa M Trejo

Yeong Shyung Chou

A method of both coating a substrate with aluminum oxide and infusing the substrate with elemental aluminum is disclosed. In one example, the method includes providing a metal powder/polymer binder slurry, the slurry having a solvent, an organic binder, metal granules and a seed element, wherein the metal granules include Al; dispersing the slurry upon a Cr-containing surface; after dispersing the slurry, exposing the slurry to air and maintaining the temperature of the slurry and substrate below 110&#xb0; C. to remove at least a portion of the solvent from the slurry; and, in a combined step, both exposing the binder, metal granules and substrate to air and heating the remaining slurry and substrate at a temperature less than or equal to 1000&#xb0; C. to both diffuse at least a portion of the metal of the metal granules into the substrate and coat the substrate with aluminum oxide.

Protective aluminum oxide surface coatings and low-temperature forming process for high-temperature applications

A system and method are detailed for aluminizing surfaces of metallic substrates, parts, and components with a protective alumina layer in-situ. Aluminum (Al) foil sandwiched between the metallic components and a refractory material when heated in an oxidizing gas under a compression load at a selected temperature forms the protective alumina coating on the surface of the metallic components. The alumina coating minimizes evaporation of volatile metals from the metallic substrates, parts, and components in assembled devices that can degrade performance during operation at high temperature.

System and process for aluminization of metal-containing substrates

A seal for a solid oxide fuel cell includes a glass matrix having glass percolation therethrough and having a glass transition temperature below 650&#xb0; C. A deformable second phase material is dispersed in the glass matrix. The second phase material can be a compliant material. The second phase material can be a crushable material. A solid oxide fuel cell, a precursor for forming a seal for a solid oxide fuel cell, and a method of making a seal for a solid oxide fuel cell are also disclosed.

Engineered glass seals for solid-oxide fuel cells

A system and method are detailed for aluminizing surfaces of metallic substrates, parts, and components with a protective alumina layer in-situ. Aluminum (Al) foil sandwiched between the metallic components and a refractory material when heated in an oxidizing gas under a compression load at a selected temperature forms the protective alumina coating on the surface of the metallic components. The alumina coating minimizes evaporation of volatile metals from the metallic substrates, parts, and components in assembled devices during operation at high temperature that can degrade performance.

A surface modification to prevent oxide scale spallation is disclosed. The surface modification includes a ferritic stainless steel substrate having a modified surface. A cross-section of the modified surface exhibits a periodic morphology. The periodic morphology does not exceed a critical buckling length, which is equivalent to the length of a wave attribute observed in the cross section periodic morphology. The modified surface can be created using at least one of the following processes: shot peening, surface blasting and surface grinding. A coating can be applied to the modified surface.

Surface modification to prevent oxide scale spallation

The present invention provides a material and a method for its creation and use wherein a reactive element, preferably a rare earth element, is included in an oxide coating material. The inclusion of this material modifies the growth and structure of the scale beneath the coating on metal substrate and improves the scale adherence to the metal substrate.

Approach for improved stability and performance of SOFC metallic interconnects

The present invention provides novel compositions that find advantageous use in making electrodes for electrochemical cells and electrochemical devices such as solid oxide fuel cells, electrolyzers, sensors, pumps and the like, the compositions comprising cerium-modified doped strontium titanate. The invention also provides novel methods for making and using anode material compositions and solid oxide fuel cells and solid oxide fuel cell assemblies having anodes comprising the compositions.

Cerium-modified doped strontium titanate compositions for solid oxide fuel cell anodes and electrodes for other electrochemical devices

Multi-layer seals are provided that find advantageous use for reducing leakage of gases between adjacent components of electrochemical devices. Multi-layer seals of the invention include a gasket body defining first and second opposing surfaces and a compliant interlayer positioned adjacent each of the first and second surfaces. Also provided are methods for making and using the multi-layer seals, and electrochemical devices including said seals.

Multi-layer seal for electrochemical devices

An electrode supported electrolyte membrane includes an electrode layerfacing an electrolyte layer. The opposing side of the electrode layerincludes a backing layerof a material with a thermal expansion coefficient approximately equal to the thermal expansion coefficient of the electrolyte layer. The backing layeris in a two dimensional pattern that covers only a portion of the electrolyte layer. An electrochemical cell such as a SOFC is formed by providing a cathode layeron an opposing side of the electrolyte layer

Supporting electrodes for solid oxide fuel cells and other electrochemical devices

A mica based compressive seal has been developed exhibiting superior thermal cycle stability when compared to other compressive seals known in the art. The seal is composed of compliant glass or metal interlayers and a sealing (gasket) member layer composed of mica that is infiltrated with a glass forming material, which effectively reduces leaks within the seal. The compressive seal shows approximately a 100-fold reduction in leak rates compared with previously developed hybrid seals after from 10 to about 40 thermal cycles under a compressive stress of from 50 psi to 100 psi at temperatures in the range from 600&#xb0; C. to about 850&#xb0; C.

Growing community of inventors

Richland, WA, United States of America

Jeffry W Stevenson