Multi-layer coating
Abstract
A multi-layer coating for protection of metals and alloys against oxidation at high temperatures is provided. The invention utilizes a multi-layer ceramic coating on metals or alloys for increased oxidation-resistance, comprising at least two layers, wherein the first layer ( 3 ) and the second layer ( 4 ) both comprise an oxide, and wherein the first layer ( 3 ) has a tracer diffusion coefficient for cations M m+ , where M is the scale forming element of the alloy, and the second layer ( 4 ) has a tracer diffusion coefficient for oxygen ions O 2− satisfying the following formula: ∫ ln p ( O 2 ) in ln p ( O 2 ) ex ( D O + m 2 D M ) ln p ( O 2 ) < 5 · 10 - 13 cm 2 / s wherein p(O 2 ) in , p(O 2 ) ex , D M , and D O are as defined herein. The coating may be used in high temperature devices, particularly for coating interconnect materials in solid oxide electrolytic devices, including solid oxide fuel cells (SOFCs) and solid oxide electrolysis cells (SOECs).
Claims
exact text as granted — not AI-modified1 - 23 . (canceled)
24 . A multilayer coating for a metal containing surface of an interconnect of a solid oxide electrolytic device, the coating comprising at least two layers:
a first layer in direct contact with the metal containing surface of the interconnect and a second layer in contact with the surrounding atmosphere, wherein both the first and second layers comprise an oxide; and wherein the first layer has a tracer diffusion coefficient for cations M m+ , with M being the scale forming element of the alloy, and the second layer has a tracer diffusion coefficient for oxygen ions O 2− satisfying the following formula:
∫
ln
p
(
O
2
)
in
ln
p
(
O
2
)
ex
(
D
O
+
m
2
D
M
)
ln
p
(
O
2
)
<
5
·
10
-
13
cm
2
/
s
wherein p(O 2 ) in is the oxygen partial pressure in equilibrium between the metal containing surface and M a O b , p(O 2 ) ex is the oxygen partial pressure in the reaction atmosphere, D M is the tracer diffusion coefficient of the metal cations M m+ in the first layer, and D O is the O 2− tracer diffusion coefficient in the second layer,
wherein the first layer comprises an oxide having a fluorite structure,
wherein the second layer comprises an oxide having a spinel structure, a rock salt structure, a corundum structure, or a wurtzite structure, and
wherein the first layer, the second layer, or both, comprises a graded composition such that the composition varies through the layer.
25 . A multilayer coating suitable for a metal containing surface of an interconnect of a solid oxide electrolytic device, the coating comprising at least two layers:
a first layer which faces the metal containing surface and a second layer facing the surrounding atmosphere, wherein both the first and second layers comprise an oxide, wherein the first layer comprises an oxide having a fluorite structure, and wherein the second layer comprises an oxide having a spinel structure, a corundum structure, a wurtzite structure, or a rock salt structure, and wherein the first layer, the second layer, or both, comprises a graded composition such that the composition varies through the layer.
26 - 27 . (canceled)
28 . A method of forming the multilayer coating of claim 24 comprising the steps of:
forming the first layer on the metal containing surface; and
depositing the second layer on the first layer.
29 . (canceled)
30 . The method of claim 28 , wherein the first layer is formed by depositing the oxide on the metal containing surface by dip-coating, slurry spraying, screen printing, spin coating, PLD, PVD, flame spraying, EPD or spray pyrolysis, and/or wherein the second layer is formed by PLD, PVD or by plasma spraying.
31 . The method of claim 28 , wherein the first layer is formed by:
depositing a metal or metal salt or metal oxide on the metal containing surface; and reacting the metal of the metal containing surface and the metal, metal salt or metal oxide so as to form the first layer.
32 . The method of claim 28 , wherein the multilayer coating is applied to a porous metal containing surface, wherein the first layer is formed by:
impregnation of the porous metal containing surface with a metal, metal salt or a metal oxide; and reacting the metal of the porous metal containing surface and metal, metal salt or metal oxide so as to form the first layer.
33 . The method of claim 28 , wherein the second layer is formed by:
impregnation of the first layer with a metal, metal salt or a metal oxide; and reacting the metal, metal salt or metal oxide so as to form the second layer on top of the first layer.
34 . The method of claim 31 , wherein the deposited metal is La, Sr, or Y.
35 . The method of claim 31 , wherein the deposited metal oxide is Y 2 O 3 , SrO, La 2 O 3 , or La 1-x Sr x CoO 3 .
36 . A solid oxide fuel cell stack, comprising the multilayer coating of claim 24 .
37 . A solid oxide electrolysis cell stack, comprising the multilayer coating of claim 24 .
38 . A method of forming the multilayer coating of claim 25 comprising the steps of:
forming the first layer on the metal containing surface; and
depositing the second layer on the first layer.
39 . The method of claim 38 , wherein the first layer is formed by depositing the oxide on the metal containing surface by dip-coating, slurry spraying, screen printing, spin coating, PLD, PVD, flame spraying, EPD or spray pyrolysis, and/or wherein the second layer is formed by PLD, PVD or by plasma spraying.
40 . The method of claim 38 , wherein the first layer is formed by:
depositing a metal or metal salt or metal oxide on the metal containing surface; and reacting the metal of the metal containing surface and the metal, metal salt or metal oxide so as to form the first layer.
41 . The method of claim 38 , wherein the multilayer coating is applied to a porous metal containing surface, wherein the first layer is formed by:
impregnation of the porous metal containing surface with a metal, metal salt or a metal oxide; and reacting the metal of the porous metal containing surface and metal, metal salt or metal oxide so as to form the first layer.
42 . The method of claim 38 , wherein the second layer is formed by:
impregnation of the first layer with a metal, metal salt or a metal oxide; and reacting the metal, metal salt or metal oxide so as to form the second layer on top of the first layer.
43 . The method of claim 40 , wherein the deposited metal is La, Sr, or Y.
44 . The method of claim 40 , wherein the deposited metal oxide is Y 2 O 3 , SrO, La 2 O 3 , or La 1-x Sr x CoO 3 .
45 . A solid oxide fuel cell stack, comprising the multilayer coating of claim 25 .
46 . A solid oxide electrolysis cell stack, comprising the multilayer coating of claim 25 .Cited by (0)
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