Abstract
Efforts in this quarter were concentrated on developing vacuum processing procedures to produce thinner (<4 {micro}m-thick), defect-free films over larger areas (>100 cm{sup 2}). We continued to test three different types of rigid supporting substrates, thermally oxidized silicon (10 cm diameter), polished borosilicate glass (10 cm diameter), and soda-lime glass (>100 cm{sup 2} areas), each representing a different cost, surface roughness, and chemistry. Mechanical integrity, defect density, and release characteristics of the films, though similar for the oxidized silicon and borosilicate glass, were distinctly different for the inexpensive soda-lime (float) glass; i.e., more sensitive to surface impurities. In general, films less than 4 {micro}m-thick were shown to be very sensitive to surface condition of the supporting substrate, particularly in the case of the soda-lime glass, to the point where surface strain overrode and dominated the intrinsic bulk stresses that are produced during the growth process. Therefore, in the near term (over the next quarter), large area films (>100 cm{sup 2}) will be produced at a minimum thickness of 5 {micro}m while further development will be conducted in subsequent quarters to reduce membrane thickness in large area films. Continued hydrogen permeation experiments and characterization of 5 and 10 {micro}m-thick, Pd-Cu films, with compositions near the 60/40 (Pd/Cu phase boundary) in combination with air oxidation treatments to improve performance. Pure hydrogen permeability for an as-received, 5 {micro}m film at 400 C was determined to be 1.3 x 10{sup -4} cm{sup 3}(STP) {center_dot} cm/cm{sup 2} {center_dot} s {center_dot} cmHg{sup 0.5} at steady state. Even a membrane {approx} 10 {micro}m-thick, exhibited a steady state hydrogen flux of 32 cm{sup 3}(STP)/cm{sup 2}min after air exposure, which, when normalized for DOE's Office of Fossil Energy's specified hydrogen flux with a {Delta}P of 100 psi and a permeate pressure of 50 psia, results in a flux of 155 scf/h/ft{sup 2} (exceeding the 2007 target by 55% and 77% of the 2010 target). Finally, on May 25, we presented a poster at the Hydrogen Program Review in Washington.
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