Sintered ceramic component and a process of forming the same

Patent metadata

Field	Value
Publication number	US-2016130184-A1
Application number	US-201514928526-A
Country	US
Kind code	A1
Filing date	Oct 30, 2015
Priority date	Nov 10, 2014
Publication date	May 12, 2016
Grant date	—

Abstract

A sintered ceramic component can have a final composition including at least 50 wt. % MgO and at least one desired dopant, wherein each dopant of the at least one desired dopant has a desired dopant content of at least 0.1 wt. %. All impurities (not including the desired dopant(s)) are present at a combined impurity content of less than 0.7 wt. %. A remainder can include Al 2 O 3 . The selection of dopants can allow for better control over the visual appearance of the sintered ceramic component, reduces the presence of undesired impurities that may adversely affect another part of an apparatus, or both. The addition of the dopant(s) can help to improve the sintering characteristics and density as compared to a sintered ceramic component that includes the material with no dopant and a relatively low impurity content.

First claim

What is claimed is:

1 . A sintered ceramic component having a final composition comprising:
at least 50 wt. % MgO; at least one desired dopant, wherein each dopant of the at least one desired dopant has a desired dopant content of at least 0.1 wt. %; all impurities are present at a combined impurity content of less than 0.7 wt. %; and a remainder comprising Al 2 O 3 .

2 . The sintered ceramic component of claim 1 , wherein the at least one desired dopant includes CaO.

3 . The sintered ceramic component of claim 2 , wherein the CaO content is at least 0.2 wt. %.

4 . The sintered ceramic component of claim 1 , wherein the at least one desired dopant includes Y 2 O 3 .

5 . The sintered ceramic component of claim 4 , wherein the Y 2 O 3 content is no greater than 3 wt. %.

6 . The sintered ceramic component of claim 1 , wherein the at least one desired dopant includes TiO 2 .

7 . The sintered ceramic component of claim 6 , wherein the TiO 2 content is no greater than 3 wt. %

8 . The sintered ceramic component of claim 1 , wherein the at least one dopant includes a first dopant and a second dopant.

9 . The sintered ceramic component of claim 1 , wherein MgO has a content that is in a range of 51 wt. % to 80 wt. %.

10 . The sintered ceramic component of claim 1 , wherein Al 2 O 3 has a content that is in a range of 20 wt. % to 49 wt. %.

11 . The sintered ceramic component of claim 1 , wherein the sintered ceramic component is a gas manifold.

12 . The sintered ceramic component of claim 1 , wherein the sintered ceramic component is a component of a gas-to-liquid membrane system.

13 . The sintered ceramic component of claim 1 , wherein the sintered ceramic component has a coefficient of thermal expansion from 25° C. to 1200° C. in a range of 9.0 ppm/° C. to 13.0 ppm/° C.

14 . A process of forming a sintered ceramic component comprising:
combining a binder and at least one powder to form a green mixture, wherein the at least one powder includes:
at least 50 wt. % MgO;
at least one desired dopant, wherein each dopant of the at least one desired dopant has a desired dopant content of at least 0.1 wt. %;
all impurities are present at a combined impurity content of less than 0.7 wt. %; and
a remainder comprising Al 2 O 3 ;
shaping the green mixture to form an object having a shape corresponding to the sintered ceramic component; and sintering the object to form the sintered ceramic component having a final composition, wherein sintering is performed at a temperature less than 1600° C., and the sintered ceramic component has a density that is at least 90% of theoretical density.

15 . The process of claim 14 , wherein sintering is performed at a temperature no greater than 1575° C.

16 . The process of claim 14 , wherein the at least one desired dopant includes CaO.

17 . The process of claim 14 , wherein the at least one desired dopant includes Y 2 O 3 .

18 . The process of claim 14 , wherein the at least one desired dopant includes TiO 2 .

19 . The process of claim 14 , wherein the at least one dopant includes a first dopant and a second dopant.

20 . The process of claim 14 , wherein the sintered ceramic component has a coefficient of thermal expansion from 25° C. to 1200° C. in a range of 9.0 ppm/° C. to 13.0 ppm/° C., 10.3 ppm/° C. to 12.7 ppm/° C., or 10.6 ppm/° C. to 12.5 ppm/° C.

Assignees

• Saint Gobain Ceramics
• Saint Gobain Ct Recherches

Inventors

• Lin Guangyong
• Narendar Yeshwanth
• Lacourse Brian C
• Robbins Wesley R
• Urffer Daniel René

Classifications

• H01M8/1246

  the electrolyte consisting of oxides · CPC title

• H01M8/2485

  Arrangements for sealing external manifolds; Arrangements for mounting external manifolds around a stack · CPC title

• C04B35/04 Primary

  based on magnesium oxide · CPC title

• H01M2008/1293

  Fuel cells with solid oxide electrolytes · CPC title

• C04B2235/9607

  Thermal properties, e.g. thermal expansion coefficient · CPC title