Cr Evaporation Research Articles

(Digital Presentation) Reactive Evaporation of Cr Vapors from Chromia-Alkaline Oxide Mixtures Generated in 800℃ Air and Subsequent Condensation Onto Aluminosilicate Fibers

This research aims to improve fundamental understanding of the reactive evaporation and condensation of Chromium (Cr) vapors, which are generated from Cr containing alloys used in many high-temperature (>500℃) process environments and can form potentially problematic condensed hexavalent (Cr(VI)) species downstream. This study focuses on the effects of alkaline oxides present in the Cr source on the resultant Cr evaporation and condensation. Vapor species were generated by flowing high-temperature (800℃) air containing 3% water vapor over chromia (Cr2O3) and mixtures of chromia with calcium oxide (CaO) or magnesium oxide (MgO) powders. Lab-grade quartz and alumina fiber samples were positioned downstream from the Cr-alkaline oxide source where the temperature decreases (<500℃) to collect condensed vapor species. Total condensed Cr and ratios of oxidation states were measured using inductively coupled plasma optical emission spectroscopy (ICP-OES) and diphenyl carbazide (DPC) colorimetric/direct UV-VIS spectrophotometric analyses. Preliminary results indicate a decrease in partial pressures of generated Cr vapor species as well as a decrease in condensed Cr species on the aluminosilicate fibers when alkaline oxides are present in the Cr source compared to a pure Cr source. These results also indicate presence of hexavalent Cr (Cr(VI)) species condensed on all samples investigated. Computational thermodynamic equilibrium modelling corroborated the experimental results showing partial pressures of produced vapor species in the presence of alkaline oxides as well as stabilities of condensed Cr compounds on the fiber samples. Comparative results and analyses are presented and discussed to help inform mechanistic understanding and future related research and engineering efforts. Figure 1

Parameters Optimization for Electrophoretic Deposition of Mn1.5Co1.5O4 on Ferritic Stainless Steel Based on Multi-Physical Simulation

Solid oxide fuel cells (SOFCs) are an effective and sustainable energy conversion technology. As operating temperatures decrease, metal interconnects and supports are widely employed in SOFCs. It is critical to apply a protective coat on ferritic stainless steel (FSS) to suppress Cr evaporation and element interdiffusion under high temperatures. Electrophoretic deposition (EPD) is a promising approach for depositing metal oxides on FSS substrate. Here, a method based on 3D multi-physical simulation and orthogonal experimental design was proposed to optimize deposition parameters, including applied voltage, deposition time, and electrode distance. The EPD process to deposit Mn1.5Co1.5O4 particles in a suspension of ethanol and isopropanol was simulated and the effects of these three factors on the film thickness and uniformity were analyzed. The results indicate that applied voltage has the greatest impact on deposition thickness, followed by deposition time and electrode distance. Meanwhile, deposition time exhibits a more significant effect on film unevenness than applied voltage. Additionally, the particle-fluid coupling phenomenon was analyzed during the EPD process. In practice, these deposition parameters must be selected appropriately and the deposition time must be controlled to obtain a uniform coating. The proposed method can reduce cost and shorten the design period.

Pre-oxidation of porous ferritic Fe22Cr alloys for lifespan extension at high-temperature

Pre-oxidation of porous ferritic Fe22Cr alloys was extensively studied in this paper. Weight gain measurements and SEM analysis revealed that pre-oxidation performed at 900°C for 40 min increased the lifespan of the alloy. A Cr evaporation study did not disclose any significant influence of the pre-oxidation process on the Cr content in the alloy. For a more detailed assessment, TEM imaging and X-ray tomography measurements of pre-oxidized samples were performed. These analyses showed that alteration in the grain and grain boundary diffusion fluxes might be the key for explaining the corrosion prevention role of pre-oxidation.

Impact of CeCo-Coated Metallic Interconnectors on SOCs Towards Performance, Cr-Oxide-Scale, and Cr-Evaporation

The performance of a solid oxide cell (SOC) depends on the operating environment. Regarding single cell tests with ideal contacting (gold, platinum, nickel meshes) and inert flow fields (Al2O3), performance is limited by intrinsic losses in the cell. Contact losses and poisoning effects are minimized. In a SOC-stack with metallic interconnectors, performance is affected by contact resistances, chromium (Cr) evaporation, and limitations in gas supply. Here, 1 cm2 single cells were tested with a stack-like contact applying metallic flow fields made from three different steel grades (Crofer 22 APU, AISI 441, UNS S44330) with and without a cerium-cobalt PVD-coating. Cell performance and losses were analyzed by IV-characteristics, impedance spectroscopy, and DRT analysis. For all uncoated interconnectors, significant performance losses due to increased contact losses and air electrode polarization were observed, which is attributed to Cr-oxide scale formation on the metallic interconnectors and Cr-poisoning of the air electrode as revealed by scanning electron microscopy-energy-dispersive X-ray spectroscopy. A CeCo-coating leads to similar oxide scales irrespective of the substrate material. Moreover, with the coating the electrochemical performance drastically improved due to decreased contact losses and an effective blocking of Cr-evaporation leading to a cell performance close to the ideal case for all three steel grades.

Evaluation of selected Fe–Cr steels under single- and dual-atmosphere conditions for intermediate-temperature solid oxide fuel cell interconnect applications

For Intermediate-Temperature SOFC, the lower operating temperature allows for a broader range of steel grades to be used as interconnects. This work compares the oxidation performances of six Cr2O3-forming steels and one Al2O3-forming steel, under single- and dual-atmosphere conditions.Single-atmosphere exposures in combination with Cr(VI) evaporation measurements were carried out at 600 °C. Except for AISI 430 all the Cr2O3-forming steels showed protective behaviour with similar Cr(VI) evaporation values and low area specific resistance (ASR) values. Kanthal EF101 showed the lowest level of Cr(VI) vaporisation but substantially higher ASR values.Dual-atmosphere exposures were carried out at 600 °C in Ar-5%H2–3%H2O//air-3%H2O. All Cr2O3-forming steels suffered various degrees of breakaway corrosion. Therefore, operation under dual-atmosphere conditions is likely the life-time-limiting failure mode.

Reactive Condensation of Cr Vapor on Aluminosilicates Containing Alkaline Oxides

The research presented herein is part of a larger project delving into the mechanisms and pathways for reactive condensation of Chromium (Cr) vapors in high-temperature (>500o C) environments. The overall goal of this research project is to improve fundamental understanding of reactive condensation pathways for chromium (Cr) vapors generated in high-temperature systems such as exhaust manifolds, steam turbines, boilers, or solid oxide fuel cells (SOFCs). Reactive evaporation of Cr from stainless steels commonly used in these systems is well-documented; however, the interactions between volatilized Cr species and surrounding interfaces during complex and dynamic system exposures is poorly understood. Understanding the interactions between volatilized Cr species and downstream components during operation is critical for improving system performance, environmental health, and safety as some condensed Cr forms toxic hexavalent Cr(VI) species. The focus of this study is on the effects of alkaline oxides present within the substrate material on reactive condensation mechanisms of Cr vapors. Studying the reaction mechanisms between Cr vapors and ceramic surfaces has direct application to SOFCs as these materials are widely used in the field. For example, alumina-silica glass-ceramics are used as sealants in SOFCs. These materials belong to the SiO2–Al2O3 system and contain different compositions of oxides including CaO, Na2O, MgO, K2O, B2O3, Y2O3, and BaO. Another sealing material used in SOFCs is mica, a class of silicate minerals that forms into distinct layers. Two types of mica commonly used in SOFC applications are muscovite (potassium aluminum silicate hydroxide fluoride, KAl2(AlSi3O10)(F,OH)2), and phlogopite (potassium magnesium aluminum silicate hydroxide, KMg3(AlSi3O10)(OH)2). The specific research objective is to explore the effects of alkaline oxide additives in aluminosilicates on Cr collection and speciation. To accomplish this objective, an experimental platform was designed to assess interactions between samples of high-temperature steel alloys or Cr oxide (Cr2O3) powder with ceramic insulating materials. The chemical composition of the insulating materials used in this study range from pure silica (SiO2) and alumina (Al2O3) to combinations thereof with and without inclusions of alkaline earth metals (e.g., Ca, Mg). Preliminary results show three- to four-fold increases in Cr(VI) formation on silica fibers with weight percentages of ~30 and ~40 percent alkaline oxides (CaO and MgO), respectively, after exposure to volatile Cr species, relative to low-alkaline silica. Figure 1 presents an overview of the experimental concept, Cr(VI) test kit, and preliminary results for dependency on alkaline oxide content. Figure 1

Long-term oxidation and chromium evaporation behavior of Al2O3-forming austenitic stainless steel for 900 °C balance-of-plant components applications in solid oxide fuel cells

The long-term operation of balance-of-plant (BoP) components in solid oxide fuel cells (SOFCs) relies on the presence of a stable and durable oxide layer. In this study, we investigate the oxidation and chromium (Cr) evaporation behaviors of two developmental alumina-forming austenitic (AFA) alloys compared to chromia-forming alloy 625 at 900 °C in air with 10% water vapor. Transpiration tests, weight gain tests, X-ray diffraction, scanning electron microscopy with energy dispersive X-ray analysis, and scanning transmission electron microscopy with energy dispersive X-ray analysis are employed to evaluate the oxidation and Cr evaporation behaviors. Our findings reveal that alloy 625 exhibits significantly higher rates of Cr evaporation compared to OC11 (Y and Hf additions) and OC11LZ (Y and Zr additions), with evaporation amounts ∼56 and ∼28 times greater, respectively. The observed differences between OC11 and OC11LZ can be attributed to variations in the formed oxide scales during long-term operation. Furthermore, we examine the influence of Hf and Zr reactive elements on the long-term oxidation and chromium evaporation behaviors, providing insights into the role of these elements in enhancing the performance and stability of the alloys.

Cr3C2 assisted ultrafast high-temperature sintering of TiC

The strong covalent bonding of TiC renders its densification through conventional sintering difficult. Here, we propose a method involving liquid-phase-assisted ultrafast high-temperature sintering (UHS) for obtaining nearly full density of TiC ceramics by the addition of Cr3C2. The samples were heated at a rate of 600 °C/min to 2200 °C and held at this temperature for 1 min. The effects of sintering parameters and the Cr3C2 content on the relative density and microstructure of the sintered samples were investigated. The main causes of rapid densification were particle rearrangement associated with the Cr3C2 liquid phase, dissolution-reprecipitation associated with the solid solution, and the weak evaporation of Cr formed during UHS. In particular, the addition of Cr3C2 helped increase the hardness and elastic modulus of TiC significantly. This paper presents an effective and extensible method involving UHS for rapidly obtaining dense ceramics.

Influence of Temperature and Water Vapour on the High-Temperature Oxidation and Cr Evaporation Behaviour of High-Cr Alloys for SOFC Cathode Air Pre-Heaters

Chromium evaporation and oxide scale growth are among the key degradation mechanisms associated with Solid Oxide Fuel Cells (SOFCs). It is often underestimated how the cathode air pre-heater (CAPH) made of high Cr-containing alloys in SOFC systems can contribute to cathode degradation. This study examines the effect of exposure temperature and water content on both degradation mechanisms in Inconel 625, SS309 and AluChrom 318. For the influence of water content, samples of Inconel 625, SS309 and AluChrom 318 were isothermally exposed at 850°C in dry air and air containing 1%, 3% and 9% of H2O at a high flow rate for 168 hours. For the influence of temperature, samples of Inconel 625, SS309 and AluChrom 318 were isothermally exposed at 650°C, 750°C and 850°C in a 6.0 L/min air stream containing 3% H2O for 168 hours. The evaporated Cr (VI) species were collected using the denuder technique. The formed oxide scales were subsequently analysed using XRD and SEM/EDX. The results of the surface characterisation indicated that the oxide scales formed on Inconel 625, SS309 and AluChrom 318 at high temperatures were Cr2O3, (Cr,Mn)3O4 spinel and Al2O3, respectively.The results of this study show that Cr evaporation and oxidation rates were dramatically reduced at the lower temperature used for Inconel 625 and SS309. AluChrom 318 exhibited an increased oxidation rate with increasing temperature, but it demonstrated a reverse trend to the temperature dependent Cr evaporation compared to Inconel 625 and SS309. It was also found that the amount of Cr evaporated from an alloy solely depended on the partial pressure of Cr presented on the oxide surface. At 850°C, the total mass of evaporated Cr(VI) species was found as follows: Cr2O3 (Inconel 625) > (Cr,Mn)3O4 spinel (SS309) >> Al2O3 (AluChrom 318). However, at 650 and 750°C, the total mass of evaporated Cr(VI) species was found to be: (Cr,Mn)3O4 spinel (SS309) > Cr2O3 (Inconel 625) > > Al2O3 (AluChrom 318). The significant effect of water vapour on the three tested materials appeared to be the further enhancement of Cr2O3 evaporation. At 850°C, the amount of evaporated Cr2O3 from the alloys exposed at the same humidity level corresponded to the Cr partial pressure on the surface, as follows: Cr2O3 (Inconel 625) > (Cr,Mn)3O4 spinel (SS309) > Al2O3 (AluChrom 318). The water vapour slightly increased the growth rate of Cr2O3 and (Cr,Mn)3O4 spinel formed on the Inconel 625 and SS309 surface, respectively. However, no evidence of change in the growth rate of the alumina on AluChrom 318 under the influence of water vapour in oxidising atmosphere was observed for the tested period in this study. Figure 1

The Influence of Water Concentration on High-Temperature Reactive Evaporation and Condensation of Cr in 800°C Air

Deleterious reactive evaporation of chromium from stainless steels commonly used in solid oxide electrochemical systems is well-documented; however, interactions between Cr vapor species and surrounding interfaces during complex and dynamic system exposures is poorly understood. Understanding the interactions between Cr vapor species and downstream components during operation is critical for improving system performance and safeguarding environmental, health and safety, as many condensed Cr compounds contain toxic and carcinogenic hexavalent chromium Cr(VI). Furthermore, the interactions between volatilized Cr species and surrounding interfaces are dependent upon dynamic chemical environments. The objective of this study is to systematically investigate and report on condensation pathways of Cr vapors within representative system environments with variable water concentrations. To accomplish this objective, an experimental platform was designed to generate Cr vapor species from the reactive evaporation of chromia (Cr2O3) powder with high-temperature (>1100 K) air/H2O mixtures, and expose downstream ceramic insulation materials (e.g., aluminosilicate fibers) at reduced temperatures (<600 K). Insulation material chemical compositions investigated include pure silica (SiO2) and alumina (Al2O3) to combinations thereof with and without inclusions of alkaline earth metals (e.g., Ca, Mg, Sr). Materials are studied as a function of exposure conditions using complementary materials characterization tools such as SEM-EDX, XPS, and diphenyl carbazide reactions to assess Cr(VI) concentrations. Reactive evaporation of Cr from chromia occurs in the presence of oxygen and/or water vapor to form various Cr-containing vapor species. Thermodynamic data reveals an equilibrium partial pressure increase of several orders of magnitude at elevated (>500 K) temperatures for all Cr vapor species. In the presence of water vapor, the partial pressure of Cr oxyhydroxide (CrO2(OH)2(g)) is greater by many several orders of magnitude and becomes the dominant species up to ~1500 K. The research objective is to explore effects of water vapor in air on Cr condensation and speciation on different ceramic insulation materials. The experimental setup thus far has exposed aluminosilicate fibers to volatilized Cr species from Cr oxide powder at 1100 K for 150 hours under varying water vapor conditions: 0 vol%(dry), 3 vol%, and 10 vol% H2O. Preliminary results show an increase in Cr(VI) formation on fibers exposed to volatile Cr species as water vapor content increases. See Figure 1 for an overview of the experimental concept, Cr(VI) test kit, and preliminary results for dependency on water vapor. Analyses of these results will be presented and discussed in context of potential implications for SOFC/SOEC systems. Figure 1

Direct Utilization of Pure and Denatured Ethanol in Metal Supported Solid Oxide Fuel Cells

Metal supported solid oxide fuel cells (MS-SOFC) are integrated with high entropy alloy reforming catalyst for direct internal reforming utilization of pure ethanol, methanol, and denatured ethanol to generate electricity. Internal reforming SOFCs have advantages over the external reforming SOFCs in terms of cost, energy efficiency, and space-saving. Performance and durability with denatured ethanol, mimicking the compositions of widely commercially-available bio-ethanol, varies dramatically with the composition of the denaturant. This evaluation of bio-ethanol fuel for SOFC application extends beyond the previous literature focusing on high-purity ethanol. Mitigation of carbon deposition is critical to extend the lifetime of MS-SOFCs operating with ethanol. Conventional Ni catalyst shows rapid carbon deposition, and in contrast the HEA catalyst has excellent resistance to carbon deposition. The HEA also enables complete internal reforming without localized cooling, resulting in high power density >0.8 W/cm2 at 700°C. Long-term operation (500-1000 hours) at the operating temperature of 600-800°C will be presented. Various strategies are applied to improve the cell stability. The effect of impurities and fuel compositions on the cell performance and stability is evaluated. Other degradation factors such as Cr evaporation and catalyst agglomeration are analyzed by SEM-EDS and EIS. It is found that MS-SOFCs are promising for direct utilization of bio-ethanol, offering a path to rapid-start, carbon-neutral operation.

Metal-Supported Solid Oxide Cells for Energy Conversion, Electrolysis, and Chemical Synthesis

This talk will provide an overview and update of performance, durability, and applications of metal-supported solid oxide fuel cell (MS-SOFC) and electrolysis cell (MS-SOEC) technology developed at Lawrence Berkeley National Laboratory (LBNL). The unique LBNL symmetric cell architecture design, with thin zirconia ceramic backbones and electrolyte sandwiched between porous metal supports, offers a number of advantages over conventional all-ceramic cells, including low-cost structural materials (e.g. stainless steel), mechanical ruggedness, excellent tolerance to redox cycling, and extremely fast start-up capability. These features enable a wide variety of applications including vehicle range extenders, electrolysis for intermittent renewables, personal power generators, and distributed generation.With infiltrated catalysts, the catalyst compositions can be easily tailored to a variety of reactions, without re-optimizing the entire cell. Recent efforts have developed catalysts for internal reforming of natural gas and ethanol, steam electrolysis to produce hydrogen, oxidative coupling of methane to synthesize ethylene, and oxygen generation from air. A recent focus is 1000+ hour continuous operation with detailed post-mortem analysis. Progress on cell performance and durability for each of these applications will be discussed.Infiltrated catalysts, however, present a tradeoff between initial performance and long-term stability. Extremely high surface area promotes high electrochemical reaction rates, but also provides high surface energy leading to coarsening and facilitates Cr deposition. Recent approaches to mitigating catalyst coarsening and Cr deposition within the cathode include coatings to prevent Cr evaporation from the stainless steel components, and optimization of infiltrated catalyst processing to stabilize the microstructure during operation. The metal support structure has also been optimized for improved mass transport.

The Coating Effect on Interconnect Materials After >10 Years of Furnace Exposures

One of the key components in the SOFC stack is the interconnect which requires versatile material properties for a proper functioning, e.g., high temperature corrosion stability, low ASR degradation and low chromium evaporation. At the same time, a high production capacity needs to be reached in order to fulfil the supply demand required for GW levels. The high production capacity is realized through Alleima AB’s production line with coil-coil physical vapor deposition of coated interconnects for SOFC and SOEC applications [1].More specifically, Sanergy HT 441 is the standard material intended to be used as an SOC interconnect. The substrate is a ferritic stainless steel (ASTM 441) which is coated with thin layers of Ce and Co (<1 µm). The material can be coated on both sides using the same coating or with a different coating. At elevated temperatures the Co coating forms a protective (CoMn)3O4 spinel layer which drastically reduces Cr evaporation while the Ce layer improves the corrosion resistance by reducing the chromia scale growth at the coating/substrate interface and thereby maintaining a low and stable ASR over time.Since long-term stability is a critical property for interconnects, Alleima has over the years gathered data from furnace samples and can thus present results where some samples have been exposed at elevated temperatures during >10 years. The main results include the effect of Ce thickness or choice of substrate on mass gain and subsequent chromia growth. Selected samples with coating elements different than Co have also been investigated. Samples have been further investigated using scanning electron microscopy for cross-sections, x-ray diffraction for characterization of phases and residual stresses as well as glow discharge optical emission spectroscopy for elemental analysis.

Structure and Properties of NbMoCrTiAl High-Entropy Alloy Coatings Formed by Plasma-Assisted Vacuum Arc Deposition

The paper analyzes the structure and properties of metal, cermet, and ceramic NbMoCrTiAl high-entropy alloy (HEA) coatings formed on solid substrates by plasma-assisted vacuum arc deposition (from multicomponent gas-metal plasma through Nb, Mo, Cr, and TiAl cathode evaporation in argon and/or a mixture of argon and nitrogen). The analysis shows that all coatings represent a nanocrystalline (3–5 nm) multilayer film. The metal coating has a bcc lattice (a = 0.3146 nm). The ceramic coating has an fcc lattice (an uncertain lattice parameter due to highly smeared diffraction peaks). The coating hardness increases in the order of metal, cermet, and then ceramic, reaching 43 GPa at Young’s modulus equal to 326 GPa. When heated in air, the metal and cermet coatings start to oxidize at 630–640 °C, and the ceramic coating at 770–780 °C.

Effect of Temperature and Water Content on the Oxidation Behaviour and Cr Evaporation of High-Cr Alloys for SOFC Cathode Air Preheaters

High temperature alloys are being investigated for use in cathode air pre-heater for solid oxide fuel cell systems because of their high thermal conductivity, formability, manufacturability, and superior mechanical properties. However, it is well-known that high temperature alloys often contain a high concentration of Cr which presents a risk of evaporation and contaminating the cathode of the solid oxide fuel cell (SOFC). The oxidation and Cr2O3 evaporation mechanisms of the alloys including alloy 625, SS309, and alloy 318 have been investigated by varying temperatures and water content of the exposure atmosphere. For the influence of water content, the alloys were isothermally exposed at 850 °C in dry air and air containing 1%, 3% and 9% of H2O at a high flow rate for 168 h. For the influence of temperature, the alloys were isothermally exposed at 650 °C, 750 °C and 850 °C in a 6.0 L/min air stream containing 3% H2O for 168 h. The results of this study show that Cr2O3 evaporation and oxidation rates were dramatically reduced with decreasing temperatures for alloy 625 and SS309. Alloy 318 exhibited a decreased oxidation rate with decreasing temperature, but it demonstrated a reverse trend to the temperature-dependent Cr2O3 evaporation compared to alloy 625 and SS309. The major effect of water vapour on the three tested materials appeared to be the further enhancement of Cr2O3 evaporation.

The Influence of Water Concentration on High-Temperature Reactive Evaporation and Condensation of Cr in 800°C Air

Reactive evaporation of Cr from stainless steels used in solid oxide electrochemical systems, such as solid oxide fuel cell (SOFC) and solid oxide electrolysis cell (SOEC) systems, is well-documented as the cause of Cr poisoning; however, the condensation and interactions of volatilized Cr species onto and with surrounding interfaces during complex and dynamic system exposures is less understood. Understanding these interactions during operation is critical for improving system performance and safeguarding environmental, health and safety, as some condensed Cr forms toxic hexavalent chromium (Cr(VI)) species. The objective of this study is to investigate and report on condensation pathways of Cr vapors within representative high-temperature system environments. To accomplish this objective, Cr vapors, produced by high-temperature (800°C) air exposures of trivalent chromium (Cr(III)) oxide (Cr2O3) powder with variable moisture content, were condensed onto various ceramic materials at lower temperatures (<400°C). Both the total amount of Cr and ratios of oxidation states were measured using ICP-MS and colorimetric analyses. An increase of Cr condensation was observed with increased water content, with similar Cr(VI) to Cr(III) ratios. Results and interpretations are discussed in context of improved understanding of Cr reactive evaporation and condensation in SOFC/SOEC and related high-temperature materials and systems.

Influence of Temperature and Water Vapour on the High-Temperature Oxidation and Cr Evaporation Behaviour of High-Cr Alloys for SOFC Cathode Air Pre-Heaters

The oxidation and Cr2O3 evaporation mechanisms of the stainless steels Inconel 625, SS309 and AluChrom 318 have been investigated by varying temperatures and water content of the exposure atmosphere. The finding of this research demonstrates that Cr2O3 evaporation and oxidation rates were significantly lowered with decreasing temperature for Inconel 625 and SS309. AluChrom 318 showed a decreased oxidation rate with decreasing temperature, but it demonstrated a reverse trend to the temperature-dependent Cr2O3 evaporation compared to Inconel 625 and SS309. The major influence of water vapour on the three tested materials appeared to be the further increase of Cr2O3 evaporation.

Crystallographic characterization of U2CrN3: A neutron diffraction and transmission electron microscopy approach

In this study, neutron diffraction and transmission electron microscopy (TEM) have been implemented to study the crystallographic structure of the ternary phase U2CrN3 from pellet to nano scale respectively. Recently microstructural evaluation of this ternary phase has been performed for the first time in pellet condition, overcoming the Cr evaporation issue during the conventional sintering process. In this work for the first time, the crystallographic structure of the ordered ternary U2CrN3 phase, stabilized in pellet condition, has been obtained by implementing neutron diffraction. For this study, pellets of the composite material UN with 20 vol% CrN were fabricated by powder metallurgy by mixing UN and CrN powders followed by Spark Plasma Sintering (SPS). TEM was used to investigate the nanoscale structure with a thin lamella of the order of 100–140 nm produced by focused ion beam (FIB). The neutron data revealed the phase composition of the pellet to be primarily 54(8) wt.% U2CrN3, in good agreement with the stoichiometry of starting reagents (UN and CrN powder) and metallographic analysis. Neutron data analysis confirms that all the crystallographic sites in U2CrN3 phase are fully occupied reinforcing the fully stoichiometric composition of this phase, however, the position of the N at the 4i site was found to be closer to the Cr than previously thought. TEM and selected area electron diffraction rendered nano-level information and revealed the presence of nano domains along grain boundaries of UN and U2CrN3, indicating a formation mechanism of the ternary phase, where the phase likely nucleates as nano domains in UN grains from migration of Cr.

Novel coatings for protecting solid oxide fuel cell interconnects against the dual-atmosphere effect

A key component of a Solid Oxide Fuel Cell (SOFC) is the interconnect, which connects individual fuel cells in series to form a fuel cell stack to reach a desired electrical potential. The interconnect is exposed to air and fuel in parallel, these so-called dual-atmosphere conditions give rise to especially severe corrosion on the air-side. This work investigates coatings to mitigate this effect. Physical Vapour Deposition (PVD) CeCo-coated AISI 441 samples on the air-side and PVD metallic Al- and Al2O3-coated AISI 441 samples on the fuel-side were exposed under dual-atmosphere conditions for up to 7000 h. The evolution of the corrosion products was followed every 1000 h with an optical microscope. Scanning electron microscopy and energy-dispersive x-ray spectroscopy were performed on cross-sections of the samples after 3000 h of exposure. The SEM analysis showed that coating on the air-side improved the sample's life-time by reducing the level of Cr evaporation even in a dual-atmosphere. The use of fuel-side coatings suppressed the dual-atmosphere effect since the coatings formed a barrier to hydrogen permeation. The best results were observed with metallic Al and Al2O3 coating on the fuel-side, which drastically reduced the dual-atmosphere effect. However, the poor conductivity of Al2O3 makes its use as a coating challenging.

Understanding surface chemical processes in perovskite oxide electrodes

Significantly different surface chemical compositions in SOCs are correlated with the dynamic mass transport phenomena such as Sr segregation, Cr evaporation and redeposition and linked with the material's oxygen transport properties.