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 »
- Inventors:
-
- San Jose, CA
- Livermore, CA
- Naperville, IL
- Issue Date:
- Research Org.:
- Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
- OSTI Identifier:
- 874290
- Patent Number(s):
- 6358567
- Assignee:
- The Regents of the University of California (Oakland, CA)
- Patent Classifications (CPCs):
-
C - CHEMISTRY C23 - COATING METALLIC MATERIAL C23C - COATING METALLIC MATERIAL
Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- 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 = {Tue Jan 01 00:00:00 EST 2002},
month = {Tue Jan 01 00:00:00 EST 2002}
}
Works referenced in this record:
YBa2Cu3O7−δ thin films deposited by an ultrasonic nebulization and pyrolysis method
journal, December 1991
- DeSisto, W. J.; Henry, R. L.; Osofsky, M.
- Thin Solid Films, Vol. 206, Issue 1-2
Electrophoretic Deposition of Y2O3-Stabilized ZrO2 Electrolyte Films in Solid Oxide Fuel Cells
journal, April 1996
- Ishihara, Tatsumi; Sato, Keiji; Takita, Yusaku
- Journal of the American Ceramic Society, Vol. 79, Issue 4
Preparation of La1−xSrxMnO3 thin films by a pyrosol derived method
journal, October 1991
- Gharbage, B.; Henault, M.; Pagnier, T.
- Materials Research Bulletin, Vol. 26, Issue 10