Abstract:
An electrically-conductive mesh spacer (42) incorporated into the hydrogen and air gas flow spaces (22,24) between each anode (14) and cathode (16) and its adjacent interconnect (40) in a fuel cell stack (76). The mesh is formed of metal strands and is formed into a predetermined three-dimensional pattern to make contact at a plurality of points on the surfaces of the electrode (14,16) and the interconnect element (40). The formed mesh spacer (42) is secured as by brazing to the interconnect element at a plurality of locations to form an interconnect, which preserves the pattern during assembly of a fuel cell stack (76). The height (48') of the formed pattern is greater than the height of a gas flow space after fuel cell assembly, such that the mesh spacer is slightly compressed (48") during assembly of a fuel cell stack. Because the metal mesh is both compliant and resilient, the compressed spacer (48") is continuously urged into mechanical and electrical contact with its electrode (14,16) over all temperatures and pressures to which the fuel cell assembly may be subjected during use.
Abstract:
A method for joining two ceramic parts, or a ceramic part and a metal par t, and the joint formed thereby. The method provides two or more parts, a br aze consisting of a mixture of copper oxide and silver, a diffusion barrier, and then heats the braze for a time and at a temperature sufficient to form the braze into a bond holding the two or more parts together. The diffusion barrier is an oxidizable metal that forms either a homogeneous component of the braze, a heterogeneous component of the braze, a separate layer borderi ng the braze, or combinations thereof. The oxidizable metal is selected from the group Al, Mg, Cr, Si, Ni, Co, Mn, Ti, Zr, Hf, Pt, Pd, Au, lanthanides, and combinations thereof.
Abstract:
A method for joining together two or more ceramic and/or metal parts by providing a braze consisting of a mixture of copper oxide, silver, and ceramic particulate. The braze is placed upon the surfaces of the parts, which are then held together for sufficient time and at a sufficient temperature to cause the braze to form a bond between the parts. The addition of the ceramic particulate increases the viscosity of the braze, decreasing squeeze out, decreasing the formation of air pockets, decreases the formation of brittle phases by providing nucleation sites and increases the flexural strength of the joint.
Abstract:
In assembling an SOFC fuel cell stack from a plurality of cassettes, the mounting plate of one cassette is attached to, and insulated from, the separator plate of the next-adjacent cassette by a peripheral dielectric seal consisting of a ceramic coating and a metal braze. Materials suitable for the ceramic coating include yttrium stabilized zirconia (YSZ), zirconia toughened alumina, magnesium silicates such as the mineral forsterite, magnesium aluminates, magnesium aluminosilicates and lanthanum zirconate. The ceramic coating may be applied to the cassette's outer surface in known fashion as by physical vapor deposition, chemical vapor deposition, sputtering, and various methods of plasma spray. An underlayer of alumina may also be used to provide a redundant layer of electrical insulation.
Abstract:
High-temperature air braze filler materials composed of various ternary metal alloys are described. Noble metals (M) are added as a ternary constituent to a silver-copper oxide (Ag-CuOx) system. The silver (Ag) component is directly substituted with the noble metal to form a series of alloys. Addition of the noble metal increases the solidus and liquidus temperatures of the resulting air braze filler metals and increases temperatures under which seals and other sealing components formed from these filler metals can be employed.
Abstract:
A feedstock composition and a method of forming metal articles using powder metallurgy techniques comprise mixing metal powders and a novel aromatic binder system. The composition of the novel feedstock comprises an aromatic binder system and a metal powder. The aromatic binder system comprises an aromatic species and can further comprise lubricants, surfactants, and polymers as additives. The metal powder comprises elemental metals, metal compounds, and metal alloys, particularly for highly-reactive metals. The method of forming metal articles comprises the steps of providing and mixing the metal powder and the aromatic binder system to produce a novel feedstock. The method further comprises processing the novel feedstock into a metal article using a powder metallurgy forming technique. Metal articles formed using the present invention have an increase in carbon and oxygen contents each less than or equal to 0.2 wt % relative to the metal powder used to fabricate the article.
Abstract:
A method for joining together two or more ceramic and/or metal parts by p roviding a braze consisting of a mixture of copper oxide, silver, and cerami c particulate. The braze is placed upon the surfaces of the parts, which are then held together for sufficient time and at a sufficient temperature to c ause the braze to form a bond between the parts. The addition of the ceramic particulate increases the viscosity of the braze, decreasing squeeze out, d ecreasing the formation of air pockets, decreases the formation of brittle p hases by providing nucleation sites and increases the flexural strength of t he joint.
Abstract:
A method for joining two ceramic parts, or a ceramic part and a metal part, and the joint formed thereby. The method provides two or more parts, a braze consisting of a mixture of copper oxide and silver, a diffusion barrier, and then heats the braze for a time and at a temperature sufficient to form the braze into a bond holding the two or more parts together. The diffusion barrier is an oxidizable metal that forms either a homogeneous component of the braze, a heterogeneous component of the braze, a separate layer bordering the braze, or combinations thereof. The oxidizable metal is selected from the group Al, Mg, Cr, Si, Ni, Co, Mn, Ti, Zr, Hf, Pt, Pd, Au, lanthanides, and combinations thereof.
Abstract:
High-temperature air braze filler materials composed of various ternary metal alloys are described. Noble metals (M) are added as a ternary constituent to a silver-copper oxide (Ag-CuOx) system. The silver (Ag) component is directly substituted with the noble metal to form a series of alloys. Addition of the noble metal increases the solidus and liquidus temperatures of the resulting air braze filler metals and increases temperatures under which seals and other sealing components formed from these filler metals can be employed.