Development of Brazing Technology for Use in High- Temperature Gas Separation Equipment

The development of high-temperature electrochemical devices such as oxygen and hydrogen separators, fuel gas reformers, solid oxide fuel cells, and chemical sensors is part of a rapidly expanding segment of the solid state technology market. These devices employ an ionic conducting ceramic as the active membrane that establishes the electrochemical potential of the device, either under voltage (i.e. to carry out gas separation) or under chemical gradient (to develop an electrical potential and thereby generate electrical power). Because the device operates under an ionic gradient that develops across the electrolyte, hermiticity across this layer is paramount. That is, not only must this thin ceramic membrane be dense with no interconnected porosity, but it must be connected to the rest of the device, typically constructed from a heat resistant alloy, with a high-temperature, gas-tight seal. A significant engineering challenge in fabricating these devices is how to effectively join the thin electrochemically active membrane to the metallic body of the device such that the resulting seal is hermetic, rugged, and stable during continuous high temperature operation.