John S Hardy

US Patent:

7055733, Jun 6, 2006

Filed:

Dec 30, 2002

Appl. No.:

10/334346

Inventors:

K. Scott Weil - Richland WA, US
John S. Hardy - Richland WA, US
Jin Yong Kim - Richland WA, US

Assignee:

Battelle Memorial Institute - Richland WA

International Classification:

B23K 31/12

US Classification:

2281221, 2282481

Abstract:

A method of joining metal and ceramic parts, wherein an alumina forming metal part and a ceramic part are provided. A braze material in placed between the alumina forming metal part and the ceramic part, and the combination is then heated in an oxidizing atmosphere, preferably in air at a temperature of between 500 C. and 1300 C. The alumina forming metal parts are selected from the group consisting of high temperature stainless steels, such as Durafoil (alpha-4), Fecralloy, Alumina-coated 430 stainless steel and Crofer-22APU, and high temperature superalloys such as Haynes 214, Nicrofer 6025, and Ducraloy. The braze material is selected as a metal oxide-noble metal mixture, preferably Ag—CuO, Ag—VO, and Pt—NbO, and more preferably between 30. 65 to 100 mole % Ag in CuO.

US Patent:

7422819, Sep 9, 2008

Filed:

Jun 22, 2005

Appl. No.:

11/158369

Inventors:

Gary F. Reisdorf - Penfield NY, US
Joseph M. Keller - Grand Blanc MI, US
Subhasish Mukerjee - Rochester NY, US
Kenneth Scott Weil - Richland WA, US
John S. Hardy - Richland WA, US

Assignee:

Delphi Technologies, Inc. - Troy MI

International Classification:

H01M 2/08

US Classification:

429 35

Abstract:

In assembling an SOFC fuel cell stack from a plurality of cassettes, the mounting plate of one cassette is attached to, and insulated from, the separator plate of the next-adjacent cassette by a peripheral dielectric seal consisting of a ceramic coating and a metal braze. Materials suitable for the ceramic coating include yttrium stabilized zirconia (YSZ), zirconia toughened alumina, magnesium silicates such as the mineral forsterite, magnesium aluminates, magnesium aluminosilicates and lanthanum zirconate. The ceramic coating may be applied to the cassette's outer surface in known fashion as by physical vapor deposition, chemical vapor deposition, sputtering, and various methods of plasma spray. An underlayer of alumina may also be used to provide a redundant layer of electrical insulation.

US Patent:

7691488, Apr 6, 2010

Filed:

Jun 11, 2007

Appl. No.:

11/811633

Inventors:

Kenneth Scott Weil - Richland WA, US
John S. Hardy - Richland WA, US
Jin Yong Kim - Richland WA, US

Assignee:

Battelle Memorial Institute - Richland WA

International Classification:

B32B 15/04

US Classification:

428621, 428633, 428673, 2281245

Abstract:

A method for joining two ceramic parts, or a ceramic part and a metal part, and the joint formed thereby. The method provides two or more parts, a braze consisting of a mixture of copper oxide and silver, a diffusion barrier, and then heats the braze for a time and at a temperature sufficient to form the braze into a bond holding the two or more parts together. The diffusion barrier is an oxidizable metal that forms either a homogeneous component of the braze, a heterogeneous component of the braze, a separate layer bordering the braze, or combinations thereof. The oxidizable metal is selected from the group Al, Mg, Cr, Si, Ni, Co, Mn, Ti, Zr, Hf, Pt, Pd, Au, lanthanides, and combinations thereof.

US Patent:

7758992, Jul 20, 2010

Filed:

Nov 14, 2003

Appl. No.:

10/714180

Inventors:

Peter C. Rieke - Pasco WA, US
Gregory W. Coffey - Richland WA, US
Larry R. Pederson - Kennewick WA, US
Olga A. Marina - Richland WA, US
John S. Hardy - Richland WA, US
Prabhaker Singh - Richland WA, US
Edwin C. Thomsen - Richland WA, US

Assignee:

Battelle Memorial Institute - Richland WA

International Classification:

H01M 4/00

US Classification:

429 40, 429 30, 429 33, 429 46

Abstract:

The present invention provides novel compositions that find advantageous use in making electrodes for electrochemical cells. Also provided are electrochemical devices that include active oxygen reduction electrodes, such as solid oxide fuel cells, sensors, pumps and the like. The compositions comprises a copper-substituted ferrite perovskite material. The invention also provides novel methods for making and using the electrode compositions and solid oxide fuel cells and solid oxide fuel cell assemblies having cathodes comprising the compositions.

US Patent:

7794170, Sep 14, 2010

Filed:

Apr 22, 2005

Appl. No.:

11/112122

Inventors:

K. Scott Weil - Richland WA, US
John S. Hardy - Richland WA, US

Assignee:

Battelle Memorial Institute - Richland WA

International Classification:

F16B 7/10
H01M 10/44

US Classification:

403 50, 429 57

Abstract:

A joint for use in electrochemical devices, such as solid oxide fuel cells (SOFCs), oxygen separators, and hydrogen separators, that will maintain a hermetic seal at operating temperatures of greater than 600 C. , despite repeated thermal cycling excess of 600 C. in a hostile operating environment where one side of the joint is continuously exposed to an oxidizing atmosphere and the other side is continuously exposed to a wet reducing gas. The joint is formed of a metal part, a ceramic part, and a flexible gasket. The flexible gasket is metal, but is thinner and more flexible than the metal part. As the joint is heated and cooled, the flexible gasket is configured to flex in response to changes in the relative size of the metal part and the ceramic part brought about by differences in the coefficient of thermal expansion of the metal part and the ceramic part, such that substantially all of the tension created by the differences in the expansion and contraction of the ceramic and metal parts is absorbed and dissipated by flexing the flexible gasket.

US Patent:

8424747, Apr 23, 2013

Filed:

Apr 5, 2010

Appl. No.:

12/754167

Inventors:

Kenneth Scott Weil - Richland WA, US
John S. Hardy - Richland WA, US
Jin Yong Kim - Richland WA, US

Assignee:

Battelle Memorial Institute - Richland WA

International Classification:

B23K 31/12

US Classification:

2281221, 2282481, 228249, 228245, 428621

Abstract:

A method for joining two ceramic parts, or a ceramic part and a metal part, and the joint formed thereby. The method provides two or more parts, a braze consisting of a mixture of copper oxide and silver, a diffusion barrier, and then heats the braze for a time and at a temperature sufficient to form the braze into a bond holding the two or more parts together. The diffusion barrier is an oxidizable metal that forms either a homogeneous component of the braze, a heterogeneous component of the braze, a separate layer bordering the braze, or combinations thereof. The oxidizable metal is selected from the group Al, Mg, Cr, Si, Ni, Co, Mn, Ti, Zr, Hf, Pt, Pd, Au, lanthanides, and combinations thereof.

US Patent:

20060060633, Mar 23, 2006

Filed:

Sep 22, 2004

Appl. No.:

10/948346

Inventors:

K. Weil - Richland WA, US
Lawrence Chick - West Richland WA, US
Christopher Coyle - Pasco WA, US
John Hardy - Richland WA, US
Guanguang Xia - Pasco WA, US
Kerry Meinhardt - Kennewick WA, US
Vincent Sprenkle - Richland WA, US
Dean Paxton - Kennewick WA, US

Assignee:

Battelle Memorial Institute - Richland WA

International Classification:

H01M 2/02

US Classification:

228101000, 429034000

Abstract:

A seal formed between a metal part and a second part that will remain gas tight in high temperature operating environments which experience frequent thermal cycling, which is particularly useful as an insulating joint in solid oxide fuel cells. A first metal part is attached to an reinforcing material. A glass forming material in the positioned in between the first metal part and the second part, and a seal is formed between the first metal part and the second part by heating the glass to a temperature suitable to melt the glass forming materials. The glass encapsulates and bonds at least a portion of the reinforcing material, thereby adding tremendous strength to the overall seal. A ceramic material may be added to the glass forming materials, to assist in forming an insulating barrier between the first metal part and the second part and to regulating the viscosity of the glass during the heating step.

US Patent:

20060063057, Mar 23, 2006

Filed:

Sep 22, 2004

Appl. No.:

10/948359

Inventors:

K. Weil - Richland WA, US
Lawrence Chick - West Richland WA, US
Christopher Coyle - Pasco WA, US
John Hardy - Richland WA, US
Guanguang Xia - Pasco WA, US
Kerry Meinhardt - Kennewick WA, US
Vincent Sprenkle - Richland WA, US
Dean Paxton - Kennewick WA, US

Assignee:

Battelle Memorial Institute - Richland WA

International Classification:

H01M 2/02

US Classification:

429034000, 228101000

Abstract:

A seal formed between a metal part and a second part that will remain gas tight in high temperature operating environments which experience frequent thermal cycling, which is particularly useful as an insulating joint in solid oxide fuel cells. A first metal part is attached to a reinforcing material. A glass forming material in the positioned in between the first metal part and the second part, and a seal is formed between the first metal part and the second part by heating the glass to a temperature suitable to melt the glass forming materials. The glass encapsulates and bonds at least a portion of the reinforcing material, thereby adding tremendous strength to the overall seal. A ceramic material may be added to the glass forming materials, to assist in forming an insulating barrier between the first metal part and the second part and to regulating the viscosity of the glass during the heating step.