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Title: Colloidal spray method for low cost thin coating deposition

Abstract

A dense or porous coating of material is deposited onto a substrate by forcing a colloidal suspension through an ultrasonic nebulizer and spraying a fine mist of particles in a carrier medium onto a sufficiently heated substrate. The spraying rate is essentially matched to the evaporation rate of the carrier liquid from the substrate to produce a coating that is uniformly distributed over the surface of the substrate. Following deposition to a sufficient coating thickness, a single sintering step may be used to produce a dense ceramic coating. Using this method, coatings ranging in thickness from about one to several hundred microns can be obtained. By using a plurality of compounds in the colloidal suspension, coatings of mixed composition can be obtained. By using a plurality of solutions and separate pumps and a single or multiple ultrasonic nebulizer(s), and varying the individual pumping rates and/or the concentrations of the solutions, a coating of mixed and discontinuously graded (e.g., stepped) or continuously graded layers may be obtained. This method is particularly useful for depositing ceramic coatings. Dense ceramic coating materials on porous substrates are useful in providing improved electrode performance in devices such as high power density solid oxide fuel cells.more » Dense ceramic coatings obtained by the invention are also useful for gas turbine blade coatings, sensors, steam electrolyzers, etc. The invention has general use in preparation of systems requiring durable and chemically resistant coatings, or coatings having other specific chemical or physical properties.« less

Inventors:
 [1];  [2];  [3]
  1. (San Jose, CA)
  2. (Livermore, CA)
  3. (Naperville, IL)
Issue Date:
Research Org.:
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
OSTI Identifier:
874290
Patent Number(s):
6358567
Assignee:
The Regents of the University of California (Oakland, CA) LLNL
DOE Contract Number:  
W-7405-ENG-48
Resource Type:
Patent
Country of Publication:
United States
Language:
English
Subject:
colloidal; spray; method; cost; coating; deposition; dense; porous; material; deposited; substrate; forcing; suspension; ultrasonic; nebulizer; spraying; fine; mist; particles; carrier; medium; sufficiently; heated; rate; essentially; matched; evaporation; liquid; produce; uniformly; distributed; surface; following; sufficient; thickness; single; sintering; step; ceramic; coatings; ranging; hundred; microns; obtained; plurality; compounds; mixed; composition; solutions; separate; pumps; multiple; nebulizers; varying; individual; pumping; rates; andor; concentrations; discontinuously; graded; stepped; continuously; layers; useful; depositing; materials; substrates; providing; improved; electrode; performance; devices; power; density; solid; oxide; fuel; cells; gas; turbine; blade; sensors; steam; electrolyzers; etc; preparation; systems; requiring; durable; chemically; resistant; specific; chemical; physical; properties; fuel cell; gas turbine; solid oxide; oxide fuel; coating material; colloidal suspension; carrier medium; /427/

Citation Formats

Pham, Ai-Quoc, Glass, Robert S., and Lee, Tae H. Colloidal spray method for low cost thin coating deposition. United States: N. p., 2002. Web.
Pham, Ai-Quoc, Glass, Robert S., & Lee, Tae H. Colloidal spray method for low cost thin coating deposition. United States.
Pham, Ai-Quoc, Glass, Robert S., and Lee, Tae H. Tue . "Colloidal spray method for low cost thin coating deposition". United States. https://www.osti.gov/servlets/purl/874290.
@article{osti_874290,
title = {Colloidal spray method for low cost thin coating deposition},
author = {Pham, Ai-Quoc and Glass, Robert S. and Lee, Tae H.},
abstractNote = {A dense or porous coating of material is deposited onto a substrate by forcing a colloidal suspension through an ultrasonic nebulizer and spraying a fine mist of particles in a carrier medium onto a sufficiently heated substrate. The spraying rate is essentially matched to the evaporation rate of the carrier liquid from the substrate to produce a coating that is uniformly distributed over the surface of the substrate. Following deposition to a sufficient coating thickness, a single sintering step may be used to produce a dense ceramic coating. Using this method, coatings ranging in thickness from about one to several hundred microns can be obtained. By using a plurality of compounds in the colloidal suspension, coatings of mixed composition can be obtained. By using a plurality of solutions and separate pumps and a single or multiple ultrasonic nebulizer(s), and varying the individual pumping rates and/or the concentrations of the solutions, a coating of mixed and discontinuously graded (e.g., stepped) or continuously graded layers may be obtained. This method is particularly useful for depositing ceramic coatings. Dense ceramic coating materials on porous substrates are useful in providing improved electrode performance in devices such as high power density solid oxide fuel cells. Dense ceramic coatings obtained by the invention are also useful for gas turbine blade coatings, sensors, steam electrolyzers, etc. The invention has general use in preparation of systems requiring durable and chemically resistant coatings, or coatings having other specific chemical or physical properties.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2002},
month = {1}
}

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