3D Painted Solid Oxide Fuel Cells: A New Approach to Functional Multi Ceramic Device Fabrication

Transcription

1 3D Painted Solid Oxide Fuel Cells: A New Approach to Functional Multi Ceramic Device Fabrication Nicholas R. Geisendorfer 1,3 Hongqian Wang 1 ; Zhan Gao, PhD 1* ; Adam E. Jakus 1,3*, PhD Prof. Scott A. Barnett 1, PhD; Prof. Ramille N. Shah, PhD 1,2,3 Northwestern University 1 Materials Science and Engineering 2 Transplant Surgery 3 Simpson Querrey Institute for BioNanotechnology * Former Affiliation Evanston, IL October 3 rd, 2017

2 Let s categorize Additive Manufacturing and 3D Printing (See ASTM F42)

3 High-power energy beam Powder-Bed Primarily associated with metals Biomet (not for metals) Pratt and Whitney

4 Rapid Prototyping Primarily associated with thermoplastics

5 Additive Manufacturing and 3D Printing (See ASTM F42) Where do ceramic materials fall? 3D PAINTING

6 The Shah Tissue Engineering and Additive Manufacturing Laboratory Defining 3D Printability and creating and developing new, 3D printable materials for any and all applications.

7 JBMR A, Science Translational Medicine, (Cover) JBMR A, Advanced Functional Materials (Cover) Adv. Eng. Mat Scientific Reports In Review Acta Astronautica. (In Rev iew)

8 Hydrogel/Cell Based Inks PEGX Bioinks Particle Laden Inks 3D Painting Well beyond biological and medical applications Aqueous Based, Primarily Water Hydrophilic Multi Mat. Compatible Can Encapsulate Live Cells (Bioprinting) Organic Solvent Based Primarily Rigid Particles Multi Mat. Compatible Can t Encapsulate Live Cells

9 3D-PAINTING: A comprehensive, Materials-Centric approach to 3D-printing & Additive manufacturing Not merely different colors Completely different materials! A selection of more than 300 distinct 3D-Inks developed by the Shah TEAM Lab (...and can be mixed and modified ad infinitum)

10 3D-Paints contain the same major components as household paints, but dry much quicker!

11 Room temperature extrusion Deposition rates up to 150 mm/s* No powder beds or resin baths No Support materials required No curing or post reactions to stabilize structures Objects can be handled immediately Fe 2 O 3 16x Speed LSM One to thousands of layers 100 µm to 2 mm** fiber diameter * Maximum speed of our hardware, not material limited. ** Maximum diameter tested Real Time

12 Standard DIW and Composite Filament FDM TEAM 3D-Paints 3D-Paints 3D Paints are composed primarily of the functional particle/powder rather than of non functional polymer Solidify via rapid evaporation of solvent upon extrusion

13 Inks do not settle-out over time A Selection of 70 vol.% Particle Inks Long shelf-life (Printable for at least 24 months after synthesis)

14 Fold Flexible (roll) Fold + Cut Fold + Cut + Fuse No need to re-wet. Remain flexible for at least 4 years.

15 Efficient and Scalable Solid Oxide Fuel Cell Fabrication Via 3D-Painting US Patent Application 15/212,534 Efficient and Scalable Solid Oxide Fuel Cell Fabrication v ia Extrusion-based 3D-Printing of Liquid Inks Manuscript in Preparation

16 H2 (g) + ½ O2 (g) H2O (g) + e- at high temperature Load e - flow H 2 Anode Electrolyte Cathode O 2 H 2 O

17 Heavy Fasteners Fuel cells aren t economically viable for widespread adoption yet

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19 Binder Jetting Inkjet Binding Original and Proprietary (Inkjet Binding) Manogharan, et al. Journal of Materials (2015) Farandos et al. Electrochimica Acta (2016) Huang, et al. Advanced Materials Technologies (2017) Little microstructural control Geometry Limitations Only demonstrated electrolyte materials Size and Geometry Limitations Multi-step firing procedure Size and Geometry Limitations

20 Require a versatile and scalable process to fabricate monolithic multi-ceramic fuel cell stacks without the need for laborintensive assembly and nonfunctional, structural components

21 Apply 3D-Painting to SOFC manufacturing! 3D PAINTING

22 YSZ (w/ Fe 2 O 3 ) NiO-YSZ LSM 8x speed No drying time required. Objects can be handled immediately after being created.

23 NiO-YSZ YSZ LSM Anode Side Cathode Side Not a push-button technique, requires controlling >15 independent parameters (i.e. applied pressure, linear speed, needle offset etc. ) 23

24 3D-printed architecture maintained and desired microstructure achieved!

25 > 1 V desired < 1 Ω desired Current-Voltage Measurement Impedance Spectroscopy Relatively poor performance for now.

26 Plots courtesy of Dr. Zhan Gao Schematic courtesy of Dr. Adam Jakus Good performance, but more cumbersome fabrication and assembly not scalable!

27 Provides additional versatility in fabrication!

28 Ink system can be utilized to create thin films as well as 3D-structures

29 Shrinkage manageable by tailoring ink composition.

30 Ink versatility provides many knobs to turn for control

31 Where are we going? 3D-Painting Ink Casting The FUTURE The Present Dip Coating

32 Prof. Ramille N. Shah, PhD Adam Jakus, PhD Christoph Kenel, Dr. sc. Xin Li, PhD Shannon Taylor Phillip Lewis Jimmy Su Emma Gargus Kelly Parker Collaborators Prof. Scott A. Barnett, PhD Hongqian Wang Zhan Gao, PhD This work is supported by a NASA Space Technology Research Fellowship ramille shah@northwestern.edu nicholasgeisendorfer2016@u.northwestern.edu