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The manufacture of sintered glasses and glass-ceramics, glass Matrix composites and glass-bounded ceramics or pastes is often affected by gas bubble formation. Against this background, we studied sintering and foaming of barium silicate glass powders used as SOFC sealants using different powder milling scenarios. Sintering was measured by means of heating microscopy backed up by XPD, DTA, Vacuum Hot Extraction (VHE) and optical and electron microscopy. Foaming increased significantly as milling progressed. For moderately milled glass powders, subsequent storage in air could also promote foaming. Although the powder compacts were uniaxially pressed and sintered in air, the milling environment significantly affected foaming. The strength of this effect increased in the order Ar >> N2 < air < CO2. Conformingly, VHE studies revealed that the pores of aerated samples predominantly encapsulated CO2, even for powders milled in Ar and N2. Results of this study thus indicate that foaming is caused by carbonaceous species trapped on the glass powder surface. Foaming could be substantially reduced by milling in water and 10 wt% HCl.
Electric contacts based on silver-glass dispersions are key components in optoelectronic microsystems and control modules for medical, information & communication and energy technology in our networked society. Driven by the complexity of modern production processes and ever shorter time-to-market requirements, the fast and specific development of tailored silver-glass dispersions has become a bottleneck of technology development. Nevertheless, the underlying mechanisms of silver dissolution, transport, and reprecipitation, and the resulting micro structure evolution during firing are poorly understood. The broad literature on the precipitation of colloidal silver particles and the related processes of silver dissolution and diffusion mostly refer to very small volume fractions of silver. Transferring these results to the sintering of glass-containing silver dispersions, is therefore highly questionable. In this case, silver dissolution, electrical contact between silver particles, transport and reprecipitation take place under special conditions. This includes short diffusion lengths (particle size < 10 μm), the presence of three-phase contacts silver - glass - sintering atmosphere, as well as silver reprecipitation at the sintering contacts as the driving force of silver transport. Here, a dynamic balance of the silver concentration can be expected to result from the ratio between silver dissolution and reprecipitation. The aim of the project is to gain basic insight into the mechanisms of dissolution, transport and reprecipitation of silver in sintering silver glass dispersions. In this context, the main focus is on gaining basic knowledge about the dissolution of metallic silver in low melting oxide glasses as the limiting factor of the sintering of silver-glass composites. In particular, we will strive to gain insight into the effect of the oxygen content of the sintering atmosphere, of the oxygen dissolved in the silver particles, of silver oxide on the surface of the silver powder, of the electric contact between the silver particles, as well as the basicity of the glass. Furthermore, we strive for insights into the silver mobility and the silver concentration that can be attained (silver solubility) in oxide glasses with a low melting point. Summing up all these aspects, a closed explanatory model for silver dissolution, transport and reprecipitation during the sintering of glass silver dispersions will be introduced.
Electric contacts based on silver-glass dispersions are key components in optoelectronic microsystems and control modules for medical, information & communication and energy technology in our networked society. Driven by the complexity of modern production processes and ever shorter time-to-market requirements, the fast and specific development of tailored silver-glass dispersions has become a bottleneck of technology development. Nevertheless, the underlying mechanisms of silver dissolution, transport, and reprecipitation, and the resulting micro structure evolution during firing are poorly understood. The broad literature on the precipitation of colloidal silver particles and the related processes of silver dissolution and diffusion mostly refer to very small volume fractions of silver. Transferring these results to the sintering of glass-containing silver dispersions, is therefore highly questionable. In this case, silver dissolution, electrical contact between silver particles, transport and reprecipitation take place under special conditions. This includes short diffusion lengths (particle size < 10 μm), the presence of three-phase contacts silver - glass - sintering atmosphere, as well as silver reprecipitation at the sintering contacts as the driving force of silver transport. Here, a dynamic balance of the silver concentration can be expected to result from the ratio between silver dissolution and reprecipitation. The aim of the project is to gain basic insight into the mechanisms of dissolution, transport and reprecipitation of silver in sintering silver glass dispersions. In this context, the main focus is on gaining basic knowledge about the dissolution of metallic silver in low melting oxide glasses as the limiting factor of the sintering of silver-glass composites. In particular, we will strive to gain insight into the effect of the oxygen content of the sintering atmosphere, of the oxygen dissolved in the silver particles, of silver oxide on the surface of the silver powder, of the electric contact between the silver particles, as well as the basicity of the glass. Furthermore, we strive for insights into the silver mobility and the silver concentration that can be attained (silver solubility) in oxide glasses with a low melting point. Summing up all these aspects, a closed explanatory model for silver dissolution, transport and reprecipitation during the sintering of glass silver dispersions will be introduced.
The development of competitive thermoelectric generators using oxide ceramics and multilayer technology requires the investigation of suitable sintering procedures. The sintering of Ca3Co4O9, which is the most promising p-type oxide regarding its figure of merit, is a special challenge, as the material starts to decompose at 926 °C. Pressure-assisted sintering (PAS), as known from large-scale production of low temperature co-fired ceramics, was used to sinter multilayers of Ca3Co4O9 green tape at 900 °C with different pressures and dwell times. In-situ shrinkage measurements, microstructural investigations and electric measurements were performed. Relative density increases from 57.4 % after free sintering for 24 h to 93.7 % after 2 h of PAS with 10 MPa axial load. The combination of tape casting and PAS induces a pronounced alignment of the anisotropic grains. In comparison to freely sintered multilayers, the electrical conductivity in the casting direction is thereby strongly increased by a factor of 5. With respect to dry-pressed bars, the improvement amounts to a factor of 15. This study shows that PAS is a proper technique to produce dense Ca3Co4O9 panels with good thermoelectric properties similar to hot-pressed tablets, even in large-scale production.
Most crucial for components of complex shape or heterogeneous micro structure, precise control of sintering has decisive influence on dimensional accuracy, mechanical integrity and reliability of sintered components. In these cases, only in situ 3D high-temperature shape screening during shrinkage would allow revealing temporary sinter warpage and hereby caused potential defects. Against this background, nokra Optische Prüftechnik und Automation GmbH, HTM Reetz GmbH and BAM developed a testing device for in situ 3D shape screening for ceramic and glass-ceramic tapes up to 1000°C by means of high-temperature laser profilometry. The local repeatability of the sample-sensor distance (sample height profile) is 10 µm at 1000°C. Current work is focused on dropping these restrictions in sample shape and temperature. In a second testing device, currently being in development, samples up to 5 cm x 5 cm x 5 cm can be measured at temperatures up to 1500°C.The presentation illustrates the current state of this work and possible applications of the method.