US20070259126A1 - Method for the Production of Thin Dense Ceramic Layers - Google Patents

Method for the Production of Thin Dense Ceramic Layers Download PDF

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Publication number
US20070259126A1
US20070259126A1 US11/662,787 US66278705A US2007259126A1 US 20070259126 A1 US20070259126 A1 US 20070259126A1 US 66278705 A US66278705 A US 66278705A US 2007259126 A1 US2007259126 A1 US 2007259126A1
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United States
Prior art keywords
substrate
ceramic
layer
less
temperature
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US11/662,787
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English (en)
Inventor
Robert Vassen
Dag Hathiramani
Deltev Stover
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Forschungszentrum Juelich GmbH
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Individual
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Assigned to FORSCHUNGSZENTRUM JULICH GMBH reassignment FORSCHUNGSZENTRUM JULICH GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HATHIRAMANI, DAG, STOVER, DELTEV, VASSEN, ROBERT
Publication of US20070259126A1 publication Critical patent/US20070259126A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/123—Spraying molten metal
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/12—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
    • H01M8/124—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the process of manufacturing or by the material of the electrolyte
    • H01M8/1246—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the process of manufacturing or by the material of the electrolyte the electrolyte consisting of oxides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/12—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
    • H01M2008/1293—Fuel cells with solid oxide electrolytes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the invention relates to a method for producing ceramic layers, in particular ceramic layers with a thickness less than 100 ⁇ m and of gas-tight design.
  • Spraying techniques in particular atmospheric plasma spraying, have proven to be very suitable for producing thin layers on a substrate.
  • APS atmospheric plasma spraying
  • spray additives in the form of particles or suspensions are applied by means of a plasma jet to the surface of a substrate to be coated.
  • a plasma is a hot gas in which neutral particles dissociate and ionize due to high temperature.
  • charged particles such as electrons and ions are also present in a plasma.
  • an electric arc is generated between a cathode and an anode by means of high-frequency ignition in a plasma burner.
  • a concentrated plasma jet having a high heat content is formed that flows from the nozzle of the plasma burner at high speed.
  • the temperatures in the hottest part of the plasma cone reach higher than 20,000 K.
  • Process parameters to be set include in particular the flow rate and composition of the plasma gas and the powder carrier gas, the current, voltage, quantity of powder, particle speed and temperature, and substrate temperature, as well as the spraying distances and the relative velocities of the plasma burner and the substrate.
  • Ceramic layers produced by atmospheric plasma spraying generally have a variety of pore-like structures that may be categorized into two different types: cracks, and coarse, usually round, pores.
  • segmentation cracks and microcracks For cracks, a further distinction may be made between segmentation cracks and microcracks.
  • the former run parallel to the coating direction through multiple spray lamellae, and sometimes even through the entire layer.
  • the width of the crack opening is typically much greater than one micron.
  • the microcracks are located between the lamellae (interlamellar) or in the lamellae (intralamellar), and have much smaller crack opening widths, generally less than one micron.
  • the microcracks are interconnected like a network and consequently impart gas permeability to the layer. The gas permeability is likewise facilitated by the round-pores and segmentation cracks, in particular those that run through the entire layer.
  • the object of the invention is to provide a method for producing on a substrate thin and also gas-tight ceramic layers that in particular have a leakage rate of less than 10 ⁇ 1 mbar L/(cm 2 s) without additional thermal aftertreatment.
  • the object of the invention is attained by a method comprising the totality of features according to the main claim.
  • Advantageous embodiments of the method are stated in the claims that refer to the main claim.
  • the object of the invention is achieved by use of an atmospheric plasma spraying method in which a number of specialized parameters are adjusted while the method is being carried out.
  • a thin ceramic layer in particular having a thickness less than 100 ⁇ m, is deposited on a substrate, and the layer advantageously is gas-tight and has a leakage rate of less than 10 ⁇ 1 mbar L/(cm 2 s).
  • the above-listed process parameters may sometimes be achieved by virtue of the geometry of the plasma burner with respect to the substrate surface.
  • the parameter settings under items 4 and 5 may generally be advantageously achieved by spraying distances that are not too large; i.e. typically less than 150 mm.
  • the speed of the robotic unit and the powder feed rate are selected so that a single pass produces a suitably dense layer having a layer thickness of less than 100 ⁇ m.
  • Favorable robotic unit speeds are between 50 and 500 mm/s.
  • ceramic materials having a melting point for example zirconium oxide, as well as stabilizer additives such as perovskites, pyrochlores, aluminates, aluminum oxide, spinels, boron carbides, and titanium carbides, among others, have proven to be suitable materials for the above-referenced method.
  • the method according to the invention may be easily applied to the production of various layers, in particular for dense electrolytic layers for high-temperature fuel cells, membranes for gas separation technologies, and for oxidation- or corrosion-proof layers.
  • Porous substrates provided with an anode were preheated to temperatures of approximately 500° C., using a plasma burner. Triplex II or F4 burners by Sulzer Metco, for example, may be used as the plasma burner.
  • the power and the process gas flows were selected high enough to produce high process-gas speeds and temperatures.
  • Used as powder was a melted, crushed, fully yttrium-stabilized zirconium oxide (YSZ) having a d 50 value of 20 ⁇ m.
  • the incident particle speeds on the substrate were greater than 300 m/s, and the temperature was greater than 3000° C.
  • the spraying distance was 90 mm.
  • the substrate temperature during the coating was approximately 800° C.
  • the speed of the robotic unit and the powder feed rate were selected such that one pass produced a dense YSZ layer approximately 90 ⁇ m thick.
  • the robotic unit speed was set at 150 mm/s.
  • the YSZ layer thus produced generally had a leakage rate of less than 10 ⁇ 2 mbar L/(cm 2 S).
  • the figure shows the layer structure of the above-referenced illustrated embodiment having a porous substrate, an intermediate layer thereon, and a dense YSZ electrolytic layer thereon that was applied by the APS method according to the invention.
  • Fiber composites-made of carbon fiber composite (CFC) materials were provided with a mullite layer having cracks. This layer was coated with an additional gas-tight La 2 Hf 2 O 7 layer according to the invention as described herein in order to prevent attack by corrosive or oxidizing gases on the substrate and the mullite layer. Alternatively, a ceramic interlayer could be inserted to suppress the reactions between mullite and La 2 Hf 2 O 7 .
  • CFC carbon fiber composite
  • Spray-dried powder having a d 50 of approximately 30 ⁇ m was used to produce the dense La 2 Hf 2 O 7 layer.
  • the substrate was preheated to 400° C. using the burner (Triplex II, F4, or a higher-power burner variant).
  • the particle speed was approximately 210 m/s at temperatures of approximately 2900° C.
  • the layer produced was approximately 35 ⁇ m thick.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Laminated Bodies (AREA)
US11/662,787 2004-09-13 2005-08-04 Method for the Production of Thin Dense Ceramic Layers Abandoned US20070259126A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102004044597.4 2004-09-13
DE102004044597A DE102004044597B3 (de) 2004-09-13 2004-09-13 Verfahren zur Herstellung dünner, dichter Keramikschichten
PCT/DE2005/001380 WO2006029587A1 (de) 2004-09-13 2005-08-04 Verfahren zur herstellung dünner, dichter keramikschichten

Publications (1)

Publication Number Publication Date
US20070259126A1 true US20070259126A1 (en) 2007-11-08

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US11/662,787 Abandoned US20070259126A1 (en) 2004-09-13 2005-08-04 Method for the Production of Thin Dense Ceramic Layers

Country Status (6)

Country Link
US (1) US20070259126A1 (enExample)
EP (1) EP1789600B1 (enExample)
JP (1) JP4738414B2 (enExample)
DE (1) DE102004044597B3 (enExample)
ES (1) ES2387891T3 (enExample)
WO (1) WO2006029587A1 (enExample)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110048017A1 (en) * 2009-08-27 2011-03-03 General Electric Company Method of depositing protective coatings on turbine combustion components
US20110244216A1 (en) * 2008-02-06 2011-10-06 Alexandra Meyer Thermal barrier coating system and method for the production thereof
US9725797B2 (en) 2008-04-30 2017-08-08 United Technologies Corporation Process for forming an improved durability thick ceramic coating
US20180205094A1 (en) * 2015-09-14 2018-07-19 Elcogen Oy Protection arrangement and method of solid oxide cells
US20190136360A1 (en) * 2014-05-16 2019-05-09 Applied Materials, Inc. Plasma spray coating design using phase and stress control
US20190185982A1 (en) * 2014-12-24 2019-06-20 Nsk Ltd. Insulated bearing and bearing coating method
US10770735B2 (en) 2015-06-12 2020-09-08 Elcogen Oy Protection arrangement and method of solid oxide cells

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102008026101B4 (de) * 2008-05-30 2010-02-18 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Thermisch gespritzte Al2O3-Schichten mit einem hohen Korundgehalt ohne eigenschaftsmindernde Zusätze und Verfahren zu ihrer Herstellung
DE102013017888A1 (de) 2013-10-28 2015-04-30 Robert Brockmann Verfahren zur Verheilung der Passivschicht eines Bauteils von Aluminium zur Wiedererlangung der Gasdichtheit
US11404710B2 (en) 2018-12-17 2022-08-02 Cummins Enterprise Llc Assembled portion of a solid oxide fuel cell and methods for inspecting the same
DE102020126082A1 (de) 2020-10-06 2022-04-07 Forschungszentrum Jülich GmbH Verfahren zur Herstellung einer Beschichtung sowie Beschichtung

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US5051321A (en) * 1989-07-28 1991-09-24 Onoda Cement Company, Ltd. Solid oxide fuel cell and method of manufacturing the same
US5858470A (en) * 1994-12-09 1999-01-12 Northwestern University Small particle plasma spray apparatus, method and coated article
US5976695A (en) * 1996-10-02 1999-11-02 Westaim Technologies, Inc. Thermally sprayable powder materials having an alloyed metal phase and a solid lubricant ceramic phase and abradable seal assemblies manufactured therefrom
US6306517B1 (en) * 1996-07-29 2001-10-23 General Electric Company Thermal barrier coatings having an improved columnar microstructure
US20030057109A1 (en) * 2001-09-24 2003-03-27 Wang Da Yu Hydrogen sensing process and apparatus
US20040018409A1 (en) * 2002-02-28 2004-01-29 Shiqiang Hui Solid oxide fuel cell components and method of manufacture thereof
WO2004079033A1 (de) * 2003-03-07 2004-09-16 Forschungszentrum Jülich GmbH Verfahren zur herstellung eines schichtsystems umfassend einen metallischen träger und eine anodenfunktionsshicht
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US4172068A (en) * 1978-07-24 1979-10-23 International Minerals & Chemical Corporation Foundry core composition of aggregate and a binder therefor
US5051321A (en) * 1989-07-28 1991-09-24 Onoda Cement Company, Ltd. Solid oxide fuel cell and method of manufacturing the same
US5858470A (en) * 1994-12-09 1999-01-12 Northwestern University Small particle plasma spray apparatus, method and coated article
US6306517B1 (en) * 1996-07-29 2001-10-23 General Electric Company Thermal barrier coatings having an improved columnar microstructure
US5976695A (en) * 1996-10-02 1999-11-02 Westaim Technologies, Inc. Thermally sprayable powder materials having an alloyed metal phase and a solid lubricant ceramic phase and abradable seal assemblies manufactured therefrom
US7141271B2 (en) * 2000-08-30 2006-11-28 Siemens Power Generation, Inc. Method for producing a solid ceramic fuel cell
US20030057109A1 (en) * 2001-09-24 2003-03-27 Wang Da Yu Hydrogen sensing process and apparatus
US20040018409A1 (en) * 2002-02-28 2004-01-29 Shiqiang Hui Solid oxide fuel cell components and method of manufacture thereof
WO2004079033A1 (de) * 2003-03-07 2004-09-16 Forschungszentrum Jülich GmbH Verfahren zur herstellung eines schichtsystems umfassend einen metallischen träger und eine anodenfunktionsshicht
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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110244216A1 (en) * 2008-02-06 2011-10-06 Alexandra Meyer Thermal barrier coating system and method for the production thereof
US9725797B2 (en) 2008-04-30 2017-08-08 United Technologies Corporation Process for forming an improved durability thick ceramic coating
US20110048017A1 (en) * 2009-08-27 2011-03-03 General Electric Company Method of depositing protective coatings on turbine combustion components
US20190136360A1 (en) * 2014-05-16 2019-05-09 Applied Materials, Inc. Plasma spray coating design using phase and stress control
US10604831B2 (en) * 2014-05-16 2020-03-31 Applied Materials, Inc. Plasma spray coating design using phase and stress control
US20190185982A1 (en) * 2014-12-24 2019-06-20 Nsk Ltd. Insulated bearing and bearing coating method
US10770735B2 (en) 2015-06-12 2020-09-08 Elcogen Oy Protection arrangement and method of solid oxide cells
US20180205094A1 (en) * 2015-09-14 2018-07-19 Elcogen Oy Protection arrangement and method of solid oxide cells
US10535883B2 (en) * 2015-09-14 2020-01-14 Elcogen Oy Protection arrangement and method of solid oxide cells

Also Published As

Publication number Publication date
DE102004044597B3 (de) 2006-02-02
EP1789600A1 (de) 2007-05-30
EP1789600B1 (de) 2012-05-30
ES2387891T3 (es) 2012-10-03
WO2006029587A1 (de) 2006-03-23
JP4738414B2 (ja) 2011-08-03
JP2008512566A (ja) 2008-04-24

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