Abstract: A solid oxide fuel cell (SOFC) system included high thermal conductivity materials such as copper to increase thermal energy transfer by thermal conduction. The copper is protected from oxidation by nickel electroplating and protected from thermal damage by providing Hastelloy liners inside combustion chambers. Monel elements are used in the incoming air conduits to prevent cathode poisoning.

Abstract: A solid oxide fuel cell (SOFC) system included high thermal conductivity materials such as copper 10 increase thermal energy transfer by thermal conduction. The copper is protected from oxidation by nickel electroplating and protected from thermal damage by providing Hastelloy liners inside combustion chambers. Monel elements are used in the incoming air conduits to prevent cathode poisoning.

Abstract: A solid oxide fuel cell (SOFC) system included high thermal conductivity materials such as copper 10 increase thermal energy transfer by thermal conduction. The copper is protected from oxidation by nickel electroplating and protected from thermal damage by providing Hastelloy liners inside combustion chambers. Monel elements are used in the incoming air conduits to prevent cathode poisoning.

Abstract: In one aspect, a film is disclosed, which comprises at least one ceramic material, and a binder mixed with the ceramic material, where the film has a thickness in a range of about 0.01 mm to about 2.5 mm. The film is flexible with a minimum bend radius that is equal to or less than about 2 times a thickness of the film. By way of example, the minimum bend radius of the flexible film can be in a range of about the thickness of the film to about twice the thickness of the film. For example, in some embodiments, the minimum bend radius of the film can be in a range of about 0.02 mm to about 5 mm.

Abstract: A solid oxide fuel cell (SOFC) system included high thermal conductivity such as copper materials such as copper to increase thermal energy transfer by thermal conduction. The copper is protected from oxidation by nickel electroplating and protected from thermal damage by providing Hastelloy liners inside combustion chambers.

Abstract: A solid oxide fuel cell (SOFC) system includes inner and outer enclosure walls each formed as an independent thermally conductive path. Each thermally conductive path comprises materials having a coefficient of thermal conductivity of greater than 100 W/m° K. The inner and outer enclosure walls are each thermally conductively coupled with an annular enclosure formed to enclose a fuel reformer module. The annular enclosure provides a fourth thermally conductive path disposed between the inner and outer enclosure walls having a coefficient of thermal conductivity of 50 W/m° K or less. A temperature sensor and thermal fuse are mounted to an outside surface of the outer enclosure. An active sensor and a passive fuse are provided to interrupt a flow of fuel into the fuel reformer when a temperature of the outer enclosure walls equal or exceed a failsafe operating temperature.

Abstract: A solid oxide fuel cell (SOFC) system included high thermal conductivity such as copper materials such as copper to increase thermal energy transfer by thermal conduction. The copper is protected from oxidation by nickel electroplating and protected from thermal damage by providing Hastelloy liners inside combustion chambers.

Abstract: A solid oxide fuel cell (SOFC) system included high thermal conductivity materials such as copper to increase thermal energy transfer by thermal conduction. The copper is protected from oxidation by nickel electroplating and protected from thermal damage by providing Hastelloy liners inside combustion chambers. Monel elements are used in the incoming air conduits to prevent cathode poisoning.

Abstract: A rod assembly and method for supporting rods includes opposing end plates for supporting opposing ends of a plurality of solid oxide fuel cell rods with each rod comprising a hollow gas conduit passing there through. Each rod end is supported by an annular flexure configured to provide a gas/liquid tight seal between the rod ends and the end plates. Each annular flexure includes a flexible portion surrounding the rod end such that forces imparted to either or both of the rod and the end plate act to elastically deform the annular flexure without damaging the rods. The rod assembly operates and a Solid Oxide Fuel Cell (SOFC) with operating temperatures of 500 to 1000° C.

Abstract: A solid oxide fuel cell (SOFC) system includes inner and outer enclosure walls each formed as an independent thermally conductive path. Each thermally conductive path comprises materials having a coefficient of thermal conductivity of greater than 100 W/m° K. The inner and outer enclosure walls are each thermally conductively coupled with an annular enclosure formed to enclose a fuel reformer module. The annular enclosure provides a fourth thermally conductive path disposed between the inner and outer enclosure walls having a coefficient of thermal conductivity of 50 W/m° K or less. A temperature sensor and thermal fuse are mounted to an outside surface of the outer enclosure. An active sensor and a passive fuse are provided to interrupt a flow of fuel into the fuel reformer when a temperature of the outer enclosure walls equal or exceed a failsafe operating temperature.

Abstract: A solid oxide fuel cell (SOFC) system included high thermal conductivity materials such as copper to increase thermal energy transfer by thermal conduction. The copper is protected from oxidation by nickel electroplating and protected from thermal damage by providing Hastelloy liners inside combustion chambers. Monel elements are used in the incoming air conduits to prevent cathode poisoning.

Abstract: A rod assembly and method for supporting rods includes opposing end plates for supporting opposing ends of a plurality of solid oxide fuel cell rods with each rod comprising a hollow gas conduit passing there through. Each rod end is supported by an annular flexure configured to provide a gas/liquid tight seal between the rod ends and the end plates. Each annular flexure includes a flexible portion surrounding the rod end such that forces imparted to either or both of the rod and the end plate act to elastically deform the annular flexure without damaging the rods. The rod assembly operates and a Solid Oxide Fuel Cell (SOFC) with operating temperatures of 500 to 1000° C.

Abstract: A workpiece, such as a turbine engine component, comprises a substrate, a thermal barrier coating on the substrate, and a hard erosion barrier deposited over the thermal barrier coating. The erosion barrier preferably has a Vickers hardness in the range of from 1300 to 2750 kg/mm2. The erosion barrier may be formed from aluminum oxide, silicon carbide, silicon nitride, or molybdenum disilicide. The erosion barrier may be formed using either an electrophoretic deposition process or a slurry process.

Abstract: A workpiece, such as a turbine engine component, comprises a substrate, a thermal barrier coating on the substrate, and a hard erosion barrier deposited over the thermal barrier coating. The erosion barrier preferably has a Vickers hardness in the range of from 1300 to 2750 kg/mm2. The erosion barrier may be formed from aluminum oxide, silicon carbide, silicon nitride, or molybdenum disilicide. The erosion barrier may be formed using either an electrophoretic deposition process or a slurry process.

Abstract: A workpiece, such as a turbine engine component, comprises a substrate, a thermal barrier coating on the substrate, and a hard erosion barrier deposited over the thermal barrier coating. The erosion barrier preferably has a Vickers hardness in the range of from 1300 to 2750 kg/mm2. The erosion barrier may be formed from aluminum oxide, silicon carbide, silicon nitride, or molybdenum disilicide. The erosion barrier may be formed using either an electrophoretic deposition process or a slurry process.

Abstract: A refractory metal core for use in a casting system has a coating for providing oxidation resistance during shell fire and protection against reaction/dissolution during casting. In a first embodiment, the coating includes at least one oxide and a silicon containing material. In a second embodiment, the coating includes an oxide selected from the group of calcia, magnesia, alumina, zirconia, chromia, yttria, silica, hafnia, and mixtures thereof. In a third embodiment, the coating includes a nitride selected from the group of silicon nitride, sialon, titanium nitride, and mixtures thereof. Other coating embodiments are described in the disclosure.

Abstract: A refractory metal core for use in a casting system has a coating for providing oxidation resistance during shell fire and protection against reaction/dissolution during casting. In a first embodiment, the coating includes at least one oxide and a silicon containing material. In a second embodiment, the coating includes an oxide selected from the group of calcia, magnesia, alumina, zirconia, chromia, yttria, silica, hafnia, and mixtures thereof. In a third embodiment, the coating includes a nitride selected from the group of silicon nitride, sialon, titanium nitride, and mixtures thereof. Other coating embodiments are described in the disclosure.

Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.

Abstract: A refractory metal core system for use in casting a product is provided. The refractory metal core system comprises a refractory metal core and a layer of aluminum nitride deposited on the refractory metal core, which layer of aluminum nitride acts as a bond coat. The system may further comprise a layer of alumina deposited on top of the aluminum nitride layer.

Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.