Abstract: A method for joining a metal component to a ceramic component is presented. The method includes disposing a metallic barrier layer on a metallized portion of the ceramic component, and joining the metal component to the metallized portion of the ceramic component through the metallic barrier layer. The metallic barrier layer comprises nickel and a melting point depressant. The metallic barrier layer is disposed by a screen printing process, followed by sintering the layer at a temperature less than about 1000 degrees Celsius. A sealing structure including a joint between a ceramic component and a metal component is also presented.

Abstract: A method for joining a metal component to a ceramic component is presented. The method includes disposing a metallic barrier layer on a metallized portion of the ceramic component, and joining the metal component to the metallized portion of the ceramic component through the metallic barrier layer. The metallic barrier layer comprises nickel and a melting point depressant. The metallic barrier layer is disposed by a screen printing process, followed by sintering the layer at a temperature less than about 1000 degrees Celsius. A sealing structure including a joint between a ceramic component and a metal component is also presented.

Abstract: The present application provides for ceramic collars and metal rings for active brazing in sodium-based thermal batteries. The ceramic collar may be an alpha-alumina collar configured for active brazing, and thereby sealing, to outer and inner Ni rings for use in NaMx cells. The portions of the alpha-alumina collar active brazed to the outer and inner Ni rings may be outwardly facing and include inwardly extending recesses. The portions of the outer and inner Ni rings active brazed to the outwardly facing portions of the collar may be inwardly facing. The alpha-alumina collar may include a greater coefficient of thermal expansion than each of the outer and inner Ni rings, and the alpha-alumina collar and outer and inner Ni rings may be configured such that a portion of the outer and inner Ni rings is deformed into the inwardly extending recesses of the alpha-alumina collar after active brazing thereof.

Abstract: The present application provides for ceramic collars and metal rings for active brazing in sodium-based thermal batteries. The ceramic collar may be an alpha-alumina collar configured for active brazing, and thereby sealing, to outer and inner Ni rings for use in NaMx cells. The portions of the alpha-alumina collar active brazed to the outer and inner Ni rings may be outwardly facing and include inwardly extending recesses. The portions of the outer and inner Ni rings active brazed to the outwardly facing portions of the collar may be inwardly facing. The alpha-alumina collar may include a greater coefficient of thermal expansion than each of the outer and inner Ni rings, and the alpha-alumina collar and outer and inner Ni rings may be configured such that a portion of the outer and inner Ni rings is deformed into the inwardly extending recesses of the alpha-alumina collar after active brazing thereof.

Abstract: A metalized ceramic comprising a ceramic substrate comprising a first ceramic and a ceramic metallization layer disposed on the ceramic substrate. The ceramic metallization layer comprises a mixture of (i) a second ceramic and (ii) a metal comprising nickel or a refractory metal. The refractory metal may consist one or more of molybdenum, tungsten, niobium and tantalum. The first ceramic and the second ceramic have a purity of greater than about 95 percent. A method of making the metalized ceramic is provided. An electrochemical cell including the metalized ceramic is also provided.

Abstract: A method includes contacting a transition metal oxide, a sintering additive, and a grain growth inhibitor additive to form a mixture. The transition metal oxide include particles that have an average diameter less than about 1 micrometer and sintering the mixture to a temperature profile that is sufficiently high that a sintered mass is formed from the mixture. The sintering includes at least one of a microwave sintering or a spark plasma sintering. The thermal profile is less than about 1050 degrees Celsius.