Dimensional and structural control of silica aerogel membranes for miniaturized motionless gas pumps

With growing public interest in portable electronics such as micro fuel cells, micro gas total analysis systems, and portable medical devices, the need for miniaturized air pumps with minimal electrical power consumption is on the rise. Thus, the development and downsizing of next-generation thermal transpiration gas pumps has been investigated intensively during the last decades. Such a system relies on a mesoporous membrane that generates a thermomolecular pressure gradient under the action of an applied temperature bias. However, the development of highly miniaturized active membrane materials with tailored porosity and optimized pumping performance remains a major challenge. Here we report a systematic study on the manufacturing of aerogel membranes using an optimized, minimal-shrinkage sol–gel process, leading to low thermal conductivity and high air conductance. This combination of properties results in superior performance for miniaturized thermomolecular air pump applications. The engineering of such aerogel membranes, which implies pore structure control and chemical surface modification, requires both chemical processing know-how and a detailed understanding of the influence of the material properties on the spatial flow rate density. Optimal pumping performance was found for devices with integrated membranes with a density of 0.062 g cm–3 and an average pore size of 142.0 nm. Benchmarking of such low-density hydrophobic active aerogel membranes gave an air flow rate density of 3.85 sccm·cm–2 at an operating temperature of 400 °C. Such a silica aerogel membrane based system has shown more than 50% higher pumping performance when compared to conventional transpiration pump membrane materials as well as the ability to withstand higher operating temperatures (up to 440 °C). This study highlights new perspectives for the development of miniaturized thermal transpiration air pumps while offering insights into the fundamentals of molecular pumping in three-dimensional open-mesoporous materials. Keywords: aerogel membrane; miniaturized gas pump; sodium silicate; low-temperature cofired ceramics; Knudsen flow

Submicro- and Nano-Structured Porous Materials for Production of High-Intensity Exotic Radioactive Ion Beams

Sandrina Fernandes

ISOLDE, the CERN Isotope Separator On-line DEvice is a unique source of low energy beams of radioactive isotopes - atomic nuclei that have too many or too few neutrons to be stable. The facility is like a small 'chemical factory', giving the possibility of changing one element to another, by selecting the atomic mass of the required isotope beam in the mass separator, rather as the 'alchemists' once imagined. It produces a total of more than 1000 different isotopes from helium to radium, with half-lives down to milliseconds, by impinging a 1.4 GeV proton beam from the Proton Synchrotron Booster (PSB) onto special targets, yielding a wide variety of atomic fragments. Different components then extract the nuclei and separate them according to mass. The post-accelerator REX (Radioactive beam EXperiment) at ISOLDE accelerates the radioactive beams up to 3 MeV/u for many experiments. A wide international user radioactive ion beam (RIB) community investigates fundamental aspects of nuclear physics, particle and atomic physics, solid-state physics, materials science, astrophysics, biophysics and medicine. However, there are still a number of radioactive isotopes which are not accessible for experimental physics, either because it has been impossible to produce the element of interest, too low yields (number of isotopes per second measured in the beam line) are obtained or due to the higher post-acceleration energies required for the user's experiments. The aim of this thesis was to synthesize oxide and carbide porous materials, to be used as thick targets to increase the intensity of exotic RIBs. This was done by the evaluation of their radioactive isotope release properties and of their stability under irradiation conditions at high temperatures. This thesis is focused on the study of the chemical and physical processes occurring in the target system where the isotopes are produced, before these enter the ion-source system, are mass-separated and are sent to the user beam lines. The products formed in nuclear reactions between a proton beam and the target must, at a first step, diffuse from the interior of the target out to the surface and evaporate from it. Minimum delay times for the diffusion process can be realized by achieving the shortest diffusion lengths of highly-permeable, low-density, open-structure targets and by operating at the highest possible temperature so that release times are minimized and commensurate with the half-life of the isotopes of interest. Whereas until now target materials with micro-scale structures have been synthesized and used for RIB production, new porous submicro- and nano-structured materials offer the advantage of having lower diffusion activation energy of atoms and thus larger diffusion coefficient than the corresponding bulk counterpart, thanks to the increase of surface to volume ratio of these materials. The potential of this phenomenon for isotope mass separation online (ISOL) targets and many other applications is an evident drop of temperature to maintain a fast diffusion process, and higher release efficiency for the production of intense exotic isotope beams. In Chapter 1 the ISOL technique and the RIB production issues are introduced, followed by a review of recent progresses on target materials to increase yield production in the principal existing and next-generation ISOL and In-Flight facilities worldwide. Chapter 2 gives the theoretical fundamentals of diffusion and effusion in solid materials, and addresses specifically diffusion, effusion and release properties of ISOL targets. The study presented in Chapter 3 consists in the evaluation of release properties in different polycrystalline silicon carbide samples. The diffusion coefficients for Be, Na, Mg and F isotopes were extracted from off-line release measurements done at ISOLDE. The full characterization of the release time structure inherent to the physical and chemical processes of the ISOL RIB production on a submicrometric SiC target material (target SiC #334) used at ISOLDE, was made. This last target development resulted in improvement of magnesium short-lived isotopes yields. This was the first demonstration of the successful use of a submicrometric porous material as an ISOL target material, which delivered unprecedented 8x104 21Mg ions per µC. In Chapter 4, the synthesis of porous submicro- and nano-structured alumina to be used as an ISOL target, was followed by materials characterization in terms of microstructure and related with selected isotope release properties. Whenever possible, the release mechanisms were explained or proposed. The approach is relevant for the study of microstructure effects in other solid porous oxide and carbide targets, for optimization of their release performance. Chapter 5 shows the results of the TARPIPE experiment, set up within the design study task of the foreseen ISOL-type European facility called EURISOL, to investigate proton irradiation damage on typical and novel ISOL target materials under continuous proton irradiation at high temperature (> 1273 K). Materials such as SiC, Al2O3, Y2O3, C and Ta in a variety of forms were irradiated at the 72 MeV proton irradiation station of injector 1 at PSI (Paul Scherrer Institute). The effects of radiation damage on these materials were evaluated from microstructure and chemical analyses before and after irradiation by visual inspection, gamma spectroscopy, scanning electronic microscopy and electron dispersive X-ray analysis on a case-by-case basis. The moderate structure evolution of the porous oxide and carbide samples tested confirms that these materials are good candidates for high-power solid targets to be used at the existing and next generation high-power ISOL facilities, such as TRIUMF (TRI-University Meson Facility) and EURISOL (EURopean Isotope Separator On-line). In Chapter 6, the development and testing of a composite high-power alumina target for neon isotope production associated to a cold FEBIAD ion-source exposed to unprecedented proton beam intensities is reported. A 0.5 GeV proton beam from TRIUMF was used up to 25 µA, a factor 10 with respect to the present oxide targets in operation. The yields obtained were compared to the ones delivered by using a 70 µA proton beam in SiC targets at this facility. The target performance in terms of diffusion properties was evaluated. A general conclusion and discussion are given in Chapter 7. The release studies obtained with irradiation and ion implantation techniques on prospective SiC and Al2O3 matrices resulted in the identification of alternative target matrices for fast radioisotope release; this was confirmed experimentally from Na and Mg elements release efficiency determined online for a SiC target. A high-power oxide/metal composite target made of micrometric structural length scale Al2O3 pellets and Nb foils was operated online at unprecedented beam power intensities. Composite targets made of Nb foils and submicro- and nano-structured porous Al2O3 are expected to further increase yields of exotic isotopes. This ISOL target concept can be applied in the future for many other refractory insulating ceramics by using gradient microstructures and/or different ceramic/metallic combinations. Special care has to be taken, in order to minimize the stress induced by a mismatch of the coefficient of thermal expansion in the different ceramic layers and/or the underlying metallic substrate. Micro- and nano-technology fabrication techniques can be used to tailor pore and grain size distribution in ceramic and metallic complex-shaped composite materials and to shape these in compacts, monoliths and fenestrated structures. A balance between large surface area and large macropore volume for optimum target radioisotope release performance must be achieved. The resulting target material must in addition be stable at high temperatures, have good thermo-mechanical resistance and high thermal conductivity under irradiation for long irradiation time. The understanding of isotope release mechanisms in different solid materials, including the porous and dense fast-ion conductors will contribute to the production of exotic RIB at unprecedented high-intensity.

EPFL2010

Optimization of mixed conducting perovskites for the application in dense ceramic oxygen separation membranes, used in partial oxidation of natural gas to synthesis gas

Defne Bayraktar, Stefan Diethelm, Jan Van Herle

The aim in this project was the optimization of LaFeO3-based perovskite materials for oxygen separation membranes (OSM). The work was carried out by the Laboratory for High Performance Ceramics, Empa in collaboration with the Laboratory for Industrial Energy Systems, LENI, EPFL and the Ceramics Laboratory, LC, EPFL. The ceramic material of interest is a mixed conductor for oxygen ions and electrons at high temperature (800°-900°C) and therefore can separate oxygen from nitrogen with 100% selectivity when exposed to an oxygen partial pressure gradient (e.g. air vs. natural gas). In this capacity, such materials are attractive for the application of partial oxidation (POX) of natural gas (NG) to synthesis gas in an important and growing business. The crucial point in this developing technology is the chemical and mechanical stability of the membrane under the operating conditions (high temperature, PO2 gradient). Because of thermal and chemical expansion, large stress can be induced in the material, which can lead to fracturing. Additional destabilizing processes such as kinetic demixing (elemental segregation under influence of the oxygen gradient) or slow phase transformation can lead to decreased performance with time. The overall goal in this Ph.D. thesis was to address these stability problems from a combined experimental and theoretical point of view in order to develop a more detailed understanding and strategy for improving the materials properties. Experimentally, the ceramic membrane materials were synthesized with different B-site substitutions with the aim of decreasing chemical expansion. The focus lied on LaFeO3 materials substituted with Sr on A-site. Detailed characterizations of the most promising compositions were done including structural, transport, and mechanical properties.

2007

On the relationship between the microstructure and the mechanical properties of an ODS ferritic/martensitic steel

Amuthan Ramar

In the quest of materials for the first wall of the future fusion reactor, it has been shown that oxide dispersion strengthened (ODS) ferritic / martensitic (F/M) steels appear to be promising candidates. The inherent good mechanical properties supported by a good thermal conductivity, swelling resistance and low radiation damage accumulation of the base material, such as EUROFER97, are further enhanced by the presence of a fine dispersion of nanometric oxide particles. They would allow in principle for a higher operating temperature of the fusion reactor, above 550°C, which improves its thermal efficiency. In effect, their strength remains higher than the base material at high temperatures. There are however limitations to their application in the reactor, which relate to the intimate link between the microstructure and the mechanical properties. These limitations, such as an increased ductile to brittle transition temperature above room temperature relative to the base material, come directly from the role played by the oxide particles but also from their indirect impact on the overall microstructure, stemming from the procedure of elaboration of these materials. In addition, there is a lack of knowledge on their response to irradiation, which, even though it appears to be promising with a reduced irradiation induced hardening, is not very well understood. In this work we have developed and evaluated ferritic/martensitic steel, EUROFER97, strengthened by a dispersion of yttria particles. (1) The powder metallurgical process used to obtain it was optimized, (2) the basic mechanisms of hardening were identified and (3) the impact of irradiation on its microstructure and mechanical properties were investigated. In order to understand the behaviour of this class of material other oxide dispersion strengthened (ODS) ferritic/martensitic steels based on EUROFER97 and model alloys were also investigated. For the elaboration of the ODS steel the powders of atomized EUROFER97 and yttria are ball milled in a planetary ball mill and the material is compacted by hot isostatic pressing (HIP). The mechanical properties are evaluated by uniaxial tensile test, Charpy test and micro-indentation while the microstructure is investigated by optical microscopy, scanning electron microscopy and transmission electron microscopy. The focused ion beam (FIB) technique is also used. In the study of the ball milling it appears that the optimal time is 20 hours, as the X-ray peak broadening, crystallite size and hardness of the particles remain unchanged at longer times. Yttria nanoparticles clusters are no more detectable by X-ray after 2 hrs of milling, which is attributed here to their incorporation in the matrix, as opposed to dissolution in the matrix as is often suggested in the open literature. HR-TEM performed on the yttria particles before and after incorporation in the steel by ball milling shows that the yttria maintain its bcc equilibrium structure throughout the process. This could suggest that they are not dissolved during ball milling. We have clarified this point by a cross sectional examination of the EUROFER97 ball milled particles with 0.3wt% of yttria in an FIB. By X-ray EDS analysis it shows nanometric regions reach in yttrium and oxygen, which are the yttria particles embedded in the EUROFER97 particles, proving that they are not dissolved by ball milling. The mechanism at the origin of the alloy compaction during HIP was elaborated. The alloy compaction was done through HIPing at 1150°C for 2.5 hrs at a pressure of 190 MPa. This condition is shown to provide the highest bulk density, to a value close to 99.9%. In the optimization process, it is found that temperature plays a larger role than pressure for alloy compaction. The compaction appears to be mainly due to diffusion. Also, it appears that the ball milled particle size plays a major role in the alloy compaction. It is shown that smaller particles size induces better compaction, provided that the densification proceeds through diffusion flow. This further suggests to terminate the ball milling process by 20 hrs as the particles size reaches its minimum. The impact of the ball milling process on the mechanical properties was evaluated. EUROFER97 with and without ball milling, with and without oxide addition presents an average density around 99.8%. In the as received state, casted EUROFER97, atomized EUROFER97, ball milled EUROFER97 and ODS Yttria present microstructure morphology typical of tempered martensite, whereas ODS Ti presents a nano sized grain microstructure with an average grain size of 200 nm. Ball milling and HIPping does have a slight influence up to 400°C, due to the higher dislocation density induced by ball milling relative to casted EUROFER97. It becomes negligible above 400°C, since both casted and ball milled EUROFER97 present similar hardness and microstructure. In ODS Yttria, yttria presents an average particle size of 25 nm. In ODS Ti, Y-Ti-O presents an average particle size of 7 nm. In the following the identification of the hardening mechanisms in ODS F/M steels. A new model was developed to quantify the collective hardening due to different obstacles, assuming that they provide independent hardening mechanisms. The model helped identifying the dominating source of hardening in ODS F/M steels. The base of the model is the dispersion barrier strengthening model, which is given by Δσsparticle or defects = Mαμb(Nd)1/2 for the hardening due small defects or oxide particles and is given by Δσd-d = Mαμb(ρ)1/2 for the hardening due to dislocations. In this approximation, the total hardening is then given by Δσtotal = {(Δσd-d)2 + (Δσparticle or defects)2}1/2 . The model is used to explain the hardening due to oxides, dislocations and irradiation induced defects. It appears that dispersed oxides is dominating hardness up to 800°C, while following a heat treatment at 1000°C it is the dislocations that then dominate the hardness. Deformation mechanisms were investigated using differential strain rate experiments. The activation parameters, i.e. the activation volume and activation energy, were calculated. It appears that there is a decrease in the activation volume from room temperature to 400°C, which is less than 3%. At about 500°C there is a sudden drop in the activation volume that reaches a minimum at 600°C. With further increase in temperature, there is a significant raise in the activation volume. This abrupt decrease between 400°C and 600°C hints at a change in dislocation-rate controlling mechanism, marking two regimes, a low temperature one and a high temperature one. In situ TEM observations show that at low temperature the deformation is mainly due to the formation of the Orowan loops around the particle. At high temperature the activation energy is about 3.4 eV for ODS, whereas it is 1.3 eV for EUROFER97. The calculated activation energy corresponds well to the one of dislocation climb mechanism. This indicates that at high temperature the yttria particles could be overcome by climb, while at low temperature they are overcome by the Orowan mechanism. The peculiar response of the yield stress to irradiation for this class of material was rationalized using the total hardening model we developed. At a dose of 2 dpa, irradiation induced defects are higher in number density than the dispersed yttria particles, which although they are weaker than the yttria particles they can explain the significant hardening observed in the material. Conversely, the shallow impact of irradiation on ODS F/M steels at low doses, relative to base F/M steels, is explained by the fact that the amount of dispersoid is found to be higher than the density of irradiation induced defects.

EPFL2008