Abstract: A catalyst having a core comprising a composite (A) of SiC grains and a protective matrix of one or more metal oxides, such as alumina, in voids between the SiC grains, said core having a density >60% of theoretical density, and a catalytically active layer (C) containing, e.g., Ni adhered to the core. A catalyst support comprising a composite of SiC grains and a protective matrix of one or more metal oxides in voids between the SiC grains is also provided, along with a method of fabricating a catalyst core. The catalyst can be used in Fischer-TRopsch synthesis or in steam methane reforming.

Abstract: Ceramic membranes with integral seals and support, and related electrochemical cells and cell stacks. The membrane comprises a thin electrolyte layer supported on a porous electrode layer which in turn is supported on a thick ceramic support layer, preferably a ceramic electrolyte support. The support layer is divided into a plurality of self-supporting thin membrane regions by a network of thicker integrated support ribs. The thin electrolyte layer and thick ceramic support layer preferably define a sealing perimeter surrounding the porous electrode layer.

Abstract: Supported thin film membranes of ceramic materials and electrochemical cells including supported thin film membranes. The microstructure of the support is particularly well suited for the well suited for subsequent infiltration with electrochemically active species (as solutions, slurries, or salts) to enhance chemical or electrical transport to the membrane and maintains satisfactory gas flow to the membrane after infiltration. This invention may be useful in electrochemical separations or catalytic reactors including, but not limited to, solid oxide fuel cells and oxygen separation membranes.

Abstract: A dense ceramic electrolyte membrane supported by symmetrical porous ceramic electrolyte layers. The thin (t<100 microns) electrolyte layer is sandwiched between two fugitive-containing electrolyte support layers that become highly porous after firing. The heat treated fugitive-containing support layers form a skeletal structure of strongly adhered electrolyte with an interpenetrating network of pores that extends well always from the electrolyte surface. The porous layers can be infiltrated with a range of electrode materials or precursors to form a solid oxide fuel cell or other electrochemical cell as well as electrochemical cell stacks. The supported ceramic membrane provides electrochemical performance advantages and reduces warpage during sintering compared to conventional structures.

Abstract: Self-supporting thin film membranes of ceramic materials and related electrochemical cells and cell stacks. The membrane structure is divided into a plurality of self-supporting thin membrane regions by a network of thicker integrated support ribs. The membrane structure may be prepared by laminating a thin electrolyte layer with a thicker ceramic layer that forms a network of support ribs.

Abstract: The invention relates to perovskite oxide electrode materials in which one or more of the elements Mg, Ni, Cu, and Zn are present as minority components that enhance electrochemical performance, as well as electrode products with these compositions and methods of making the electrode materials. Such electrodes are useful in electrochemical system applications such as solid oxide fuel cells, ceramic oxygen generation systems, gas sensors, ceramic membrane reactors, and ceramic electrochemical gas separation systems.

Abstract: The embodiments relate to an electrochemical cell that includes a first layer including a porous ceramic layer having pore channels. The pore channels can be infiltrated with a conductive coating, and can be sufficiently large that a majority of the pore channels remain open after applying the conductive coating. The cell can include a second layer on the first layer, the second layer including a porous interlayer. The first and second layer can function as an anode or a cathode. The cell can include a third layer including a ceramic membrane, and a cathode positioned on the third layer. The embodiments also relate to a method of making an electrochemical cell.

Abstract: Ceramic laminate structures, particularly laminate structures including stabilized zirconia compositions, as well as electrodes and electrochemical cells including such laminate structures. The stabilized zirconia composition preferably are selected from scandia-stabilized zirconia and yttria-stabilized zirconia. These laminate structures enhance the overall flexural strength of the electrolyte layer while preserving high electrical conductivity. Such laminate structures may be useful in electrochemical fuel cells such as solid oxide fuel cells.

Abstract: Aqueous coating slurries useful in depositing a dense coating of a ceramic electrolyte material (e.g., yttrium-stabilized zirconia) onto a porous substrate of a ceramic electrode material (e.g., lanthanum strontium manganite or nickel/zirconia) and processes for preparing an aqueous suspension of a ceramic electrolyte material and an aqueous spray coating slurry including a ceramic electrolyte material. The invention also includes processes for depositing an aqueous spray coating slurry including a ceramic electrolyte material onto pre-sintered, partially sintered, and unsintered ceramic substrates and products made by this process.