We have investigated the effect of various dopants on the sintering characteristics of Ce0.9Gd0.1O1.95 (CGO) and found that 99% dense electrolyte pellets can be produced at the record low temperature of 800°C (as opposed to the 1400°C typically needed) by sintering Ce0.9Gd0.1O1.95 with as little 3mol% lithium. Our studies indicate that doping the CGO surface with lithium nitrate, as opposed to using alternative lithium salts, produces the largest decrease in sintering temperature. Unlike other dopants that lower the sintering temperature by altering the near grain boundary vacancy concentration, lithium lowers the sintering temperature through the formation of an intergranular liquid phase. This liquid phase allows fully dense, completely constrained CGO films to be produced on inert substrates at temperatures as low as 950°C.

Using transmission electron microscopy, we studied aluminum-containing intergranular phases and secondary-phase particles at triple-junctions in SiC (hot-pressed with aluminum, boron, and carbon additions). This study of statistical high-resolution electron microscopy of intergranular films indicated that a large fraction of the vitreous intergranular films (in the as-hot-pressed SiC) crystallized during post-annealing in argon above 1000 °C. However, brief heating to 1900 °C indeed re-melted 25% of the crystallized intergranular films. The structural transitions were reflected in the statistical width distributions of the amorphous grain-boundary layers. At triple-junctions, Al2O3, Al2OC-SiC solid solution, and mullite phases were newly identified. These phases, together with others reported before, are represented in a quaternary phase diagram for 1900 °C. It is proposed that a SiC-Al2OC liquid domain should be included in this phase diagram.

Polycrystalline SiC samples hot pressed with aluminum, boron, and carbon sintering additions (ABC-SiC) were characterized using transmission electron microscopy. The study focused on the effects of high-temperature treatment on microstructure. Three temperatures, at which considerable microstructural changes took place, were found to be critical. At a threshold temperature of approximately 1000°C, 1-nm-wide, amorphous intergranular films started to crystallize. At approximately 1300°C, lattice diffusion in SiC grains resulted in nanoprecipits, which could diffuse into grain boundaries and significantly altered composition. Quantitative microanalysis revealed doubled Al content in intergranular films after annealing at 1300°C. Except for crystallization in intergranular films and nano-precipitation in matrix grains, microstructure remained stable until 1600°C, when microstructural changes with volatile features occurred. A brief holding at 1900°C brought marked changes in microstructure, including structural change in intergranular films, dissolved nanoprecipitates, unit cell dilation, and cracking. The results indicate that ABC-SiC is highly promising in structural applications at up to 1500°C.

Solid oxide fuel cells produce electricity at very high efficiency and have very low to negligible emissions, making them an attractive option for power generation for electric utilities. However, conventional SOFC's are operated at 1000 °C or more in order to attain reasonable power density. The high operating temperature of SOFC's leads to complex materials problems which have been difficult to solve in a cost-effective manner. Accordingly, there is much interest in reducing the operating temperature of SOFC's while still maintaining the power densities achieved at high temperatures. There are several approaches to reduced temperature operation including alternative solid electrolytes having higher ionic conductivity than yttria stablilized zirconia, thin solid electrolyte membranes, and improved electrode materials. Given the proven reliability of zirconia-based electrolytes (YSZ) in long-term SOFC tests, the use of stabilized zirconia electrolytes in reduced temperature fuel cells is a logical choice. In order to avoid compromising power density at intermediate temperatures, the thickness of the YSZ electrolyte must be reduced from that in conventional cells (100 to 200 μm) to approximately 4 to 10 μm. There are a number of approaches for depositing thin ceramic films onto porous supports including chemical vapor deposition/electrochemical vapor deposition, sol-gel deposition, sputter deposition, etc. In this paper we describe an inexpensive approach involving the use of colloidal dispersions of polycrystalline electrolyte for depositing 4 to 10 μm electrolyte films onto porous electrode supports in a single deposition step. This technique leads to highly dense, conductive, electrolyte films which exhibit near theoretical open circuit voltages in H2/air fuel cells. These electrolyte films exhibit bulk ionic conductivity, and may see application in reduced temperature SOFC's, gas separation membranes, and fast response sensors.

A simple hot-pressing procedure for fabricating composites of diamond particulates in an alumina matrix at moderate applied pressures is described. Dense composites with up to 33 vol. % diamond particles are made by pressure-sintering at applied stress of 35 MPa in vacuum atmosphere. Preliminary wear tests of these composites on magnetic thin-film rigid disks show a low friction comparable to that of single crystalline diamond. Diamond/alumina composites can be an economical alternative to diamond or diamond coated materials for abrasion resistant applications.

The use of transient and steady-state 4-probe techniques for the evaluation of the limitations to performance in solid-state electrochemical devices is described. The application of sequential, bipolar square-wave current pulses to a solid polymer cell with two internal reference electrodes allows separation of the polarization behavior of the various components of the cell, and indicates the rate limiting processes in the cell. Careful design of the experimental cell and appropriate selection of current pulse width allows evaluation of fundamental kinetic and transport properties, as well as activation parameters. Steady state constant-current measurements using 4-probe cells allows in situ observation of interface stability and/or polarization as a function of time as the cell is cycling.

Procedures are described to deposit uniform layers of yttria and yttria-alumina prccursors on fine powders and whiskers of silicon nitride. The coatings were produced by aging at elevated temperatures aqueous systems containing the silicon nitride core particles, yttrium and aluminum nitrates, and urea. Optimum concentrations of the core particles, in relation to the reactants, were established to promote surface deposition of the oxide precursors. Polymeric dispersants were used effectively to prevent agglomeration of the solids during the microencapsulation process. The morphology of the powders was characterized using scanning and transmission electron microscopy. The mechanisms for the formation of the coated layers are discussed. A description is provided that allows qualitative assessment of the experimental factors that determine microencapsulation by a slurry method.

Potential and current distributions and local energy dissipation due to Joule heating in metal-superconductor junctions have been computed as a function of geometric parameters and interfacial resistance. The primary current distribution and power dissipation are highly nonuniform in the system. The secondary current distribution and power dissipation, however, become more uniform as the interfacial resistance increases. Analysis indicates that zero contact resistance is not a stable situation since the primary distribution leads to local current densities exceeding the critical current density of the superconducting phase near the corner of the junction. Local contact failure might then initiate. A finite contact resistance is necessary for a practical application, and the minimum value of the contact resistance can be estimated from the operating current density (javg) of the device and the critical current density (jcri) of the superconducting phase. To obtain an optimum value of the contact resistance, however, one further has to take into consideration the stability and reliability of the device performance, which is, in turn, directly related to the uniformity of the current distribution and power dissipation, to temperature fluctuation of the superconducting phases brought about by local power dissipation, and to the thermal management of the system. Furthermore, a nonuniform contact resistance layer of appropriate profile can redistribute the current more effectively and more uniformly and hence reduce the total power dissipation in the system for a given jmax/javg ratio obtained by a uniform resistance layer.

Inert p articulate inclusions in ceramic powder compacts can obstruct densification behavior significantly. The factors that are the causes of this decrease in the sinterability are reviewed. It is concluded that the origin of the sintering difficulty resides in defects that processes such as die compaction introduce during the initial forming of the composite powder compact. Alternative processing methods are suggested that should minimize the negative effects of the dispersed inclusion phase on densification.

Concurrent with impressive advances in advanced batteries operating at high temperatures such as the Na/Na2 Sx and Li/FeS systems, have been concerns over safety and reliability of such batteries. Accordingly, various efforts have been made to offer alternative high specific energy/power batteries operating at reduced temperatures [ 1, 2, 3 ]. However, since electrode kinetics and mass transport processes in batteries are thermally activated, lower temperature systems often present a compromise between lower power output, and enhanced reliability, safety, and economic factors. Fortunately, lower temperature systems also offer far more flexibility in cell design, allowing geometries with higher electrode surface area than would be feasible with high temperature systems, thereby reducing the necessary current densities for acceptable power output.