Fluxed lanthanum chromite for low temperature air firing

Abstract

A lanthanum chromite ceramic powder consisting essentially of 1 mol of LaCr.sub.1-x M.sub.x O.sub.3, where M is a divalent metal selected from the group of zinc, copper and mixtures thereof and x ranges from about 0.02 to 0.2, y mols of B.sub.2 O.sub.3, where y ranges from 0.0005 to 0.04, and z mols of La.sub.2 O.sub.3, where the ratio z/y ranges from 1 to 3, the powder is sintered to high density by firing a compact thereof at a temperature of about 1400.degree. C. in air or other atmosphere, and is particularly suited for use as interconnect material for solid oxide fuel cells.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the field of electroceramics and more particularly to a sinter-reactive lanthanum chromite ceramic especially suited for use in a solid oxide fuel cell.

2. Description of the Prior Art

Solid oxide fuel cells (SOFC) have high potential in producing electrical energy from cheap fuels or byproduct waste gas streams of the petrochemical and metallurgical industries. The potential of these fuel cells lies in the high efficiency of converting chemical to electrical energy and could find extensive applications in the domestic, commercial, defense, and aerospace sectors of the economy. The realization of this potential is contingent on the development of reliable and cost efficient methods of cell fabrication.

One of the solid oxide fuel cell designs resembles a heat exchanger with a honeycomb structure in which the electroactive ceramic components also serve as the structural members and eliminate the need for inert supports. This design is referred to as the monolithic solid oxide fuel cell (MSOFC). The honeycomb structure of the MSOFC is made up of thin layers of four components: (1) anode, usually made of a nickel-zirconia cermet; (2) electrolyte, made of a fully stabilized (cubic) zirconia; (3) cathode, made of strontium-doped lanthanum manganite (LaMnO.sub.3); and, (4) interconnect, made of doped lanthanum chromite (LaCrO.sub.3). The adjacent anode, electrolyte, and cathode layers make up one cell while the interconnect serves as an internal electrical connection between individual cells.

The monolithic solid oxide fuel cell offers lower material costs, the potential for reduced manufacturing costs, and a higher efficiency over other geometries and designs. However, fabrication of these cells is expected to be more complicated because the individual components in thin sheet format must be formed into multilayer sheets which are then converted into a honeycomb structure and must be cosintered at the same relatively low temperature (about 1400.degree. C.) in air. Of particular importance is the sintering behavior of the interconnect material, that is, lanthanum chromite which must be sintered to closed porosity or at least about 94% of its theoretical density.

Lanthanum chromite is a refractory material with a melting point of 2510.degree. C. which requires very high temperatures and controlled atmospheres, i.e. extremely low partial pressures of oxygen for sintering to near theoretical density. Groupp and Anderson (L. Groupp and H. U. Anderson, J. Am. Ceram. Soc., 59, 449 (1976)) have shown that LaCrO.sub.3 does not sinter in air even at temperatures as high as 1720.degree. C. According to the data reported by these investigators, LaCrO.sub.3 could be sintered to 95.3% TD only at 1740.degree. C. and in an atmosphere of nitrogen having an oxygen partial pressure of 10.sup.-11 atm. The main inhibition to densification appears to be the volatilization of chromium oxides in oxidizing atmospheres. The oxidation and volatilization of lanthanum chromite in oxidizing atmospheres at temperatures higher than 1400.degree. C. has indeed been reported by Meadowcroft and Wimmer (75th Annual Meeting of the Am. Ceram. Soc., Cincinnati, (1973) and D. B. Meadowcroft and J. M. Wimmer, Am. Ceram. Soc. Bull., vol. 58, 6I0 (1979)) and involves the oxidation of Cr(III) to Cr(VI) and formation of fugitive CrO.sub.3 which is a gas at the high temperatures of sintering. Therefore, the preparation of lanthanum chromite powders which sinter to closed porosity at temperatures below 1650.degree. C. so that Cr volatilization is minimized is critical for the development of monolithic solid oxide fuel cell fabrication technology. One method of fabricating lanthanum chromite (LaCrO.sub.3) electrodes is disclosed in U.S. Pat. No. 3,974,108. This patent teaches the preparation of strontium-doped lanthanum chromite, i.e., lanthanum chromite in which lanthanum is partly substituted by strontium, from lanthanum oxide, strontium carbonate and chromic acid by slurry mixing these materials, drying the slurry and then firing the dried powder mixture in air at temperatures in the preferred range of 1200.degree. to 1500.degree. C. The resultant fired powder is strontium-doped lanthanum chromite which sinters only at temperatures in excess of 1700.degree. C.

An alternative approach is to use sol-gel technology to prepare high surface area, i.e., very fine grain, and sinter reactive LaCrO.sub.3 powders, compacts of which sinter to full density at temperatures lower than 1700.degree. C. Reduction in sintering temperature is achieved by controlling the composition, homogeneity, grain size, and morphology of the powder. This control is brought about by solution chemistry and improved powder separation and processing technology. One such method for preparing lanthanum chromite has been disclosed by C. N. Rao et al. "Synthesis of Complex Metal Oxides Using Hydroxide, Cyanide and Nitrate Solid Solution Precursors", J. Solid State Chem., vol. 58, 29-37 (1985). This method consists of coprecipitation of lanthanum and chromium hydroxides which are intimately mixed and essentially constitute a solid solution of LaCr(OH).sub.6. This hydroxide solid solution is converted to LaCrO.sub.3 by calcination at 850.degree. C. for 12 hours.

Specifically, Rao et al. teach the coprecipitation of LaCr(OH).sub.6 by adding an aqueous nitrate solution of metal ions to a sodium hydroxide solution with subsequent extensive washing of the resultant hydroxide gel to remove sodium ions. Removal of sodium ions from the gel is required because even a very low concentration of sodium ion markedly changes the properties of the gel and degrades the properties of the resultant lanthanum chromite powder. Moreover, Rao et al. state that ammonium hydroxide base could not be used to coprecipitate a hydroxide containing a divalent metal such as magnesium or strontium which are frequently used as dopants of lanthanum chromite.

Another sol-gel method has been disclosed by U.S. Pat. No. 4,830,780, to Olson et al., for the preparation of lanthanum chromite doped with the divalent ions of magnesium, strontium, calcium or barium by coprecipitation from salt solutions of lanthanum, chromium and dopant ions with ammonium hydroxide. In this patent disclosure, extensive washing of the precipitated gel is allegedly not needed because residual ammonium ion is removed via the gas phase during powder calcination. Upon calcination at temperatures of about 600.degree. C., the gel converts to a single compound with the huttonite structure, LaCrO.sub.4, which upon further calcination at 900.degree. C. converts to pure lanthanum chromite, LaCrO.sub.3, with average particle size of about 0.5 .mu.m. The single phase composition of this powder and its fine grain size are in sharp contrast to the powder which is derived by following the teachings of Rao et al. The lanthanum chromite powder prepared according to the teachings of U.S. Pat. No. 4,830,780 could be sintered to 95.7 % theoretical density at 1650.degree. C. for 4 hours in a graphite furnace and to 78% theoretical density at 1600.degree. C. for 2 hours in a furnace with oxygen partial pressure of 10.sup.-10 atmospheres. Densification of this lanthanum chromite to the indicated densities was much better than what was achievable by the powders of the prior art, as for example, stated by Groupp and Anderson. However, this preparation method does not control the material stoichiometry well.

S. Hayashi et al. utilize another approach for lowering the sintering temperature of lanthanum chromite. In J. Mater. Sci. Lett., vol. 7, p. 457 (1988), Hayashi et al. are said to have prepared chromite powders in which chromium was partially substituted by zinc, copper or strontium/zinc. They prepared these zinc- or copper-doped chromite powders by standard ceramic techniques, that is, mixing of component oxide powders, calcination of the powder mixtures, and size reduction. Hayashi et al. formed compacts of the chromite powders by uniaxial pressing under 100 MPa pressure, followed by cold isostatic pressing under 300 MPa pressure. These compacts had a very high green density of about 60% of theoretical and upon firing in air at 1600.degree. C. for 2 hours achieved a density of about 98% of theoretical when the concentration of zinc was 10 or 15 mol % or the copper concentration was 5, 10 or 15 mol %. The sintering of the zinc- or copper-doped chromites, prepared by Hayashi et al., to high density in air, i.e., oxidizing atmosphere, is in sharp contrast to the behavior of strontium- or magnesium-doped chromites which require a reducing atmosphere. However, the sintering temperature of 1600.degree. C. for the powders of Hayashi et al. is much higher than what is needed for the fabrication of the monolithic solid oxide fuel cell.

Densification of lanthanum chromite at much lower temperatures in air has been disclosed in U.S. Pat. No. 4,749,632 to Flandermeyer et al. This was achieved by the incorporation into the lanthanum chromite of a sintering aid, that is, a compound or mixture of compounds which have melting points much lower than 1400.degree. C. For example, lanthanum chromite mixed with 10 w % boric acid powder was formed into a tape and fired at 1377.degree. C. to a density of about 94% of theoretical. Note that boric acid, H.sub.2 BO.sub.3, melts at about 160.degree. C. with simultaneous dehydration to HBO.sub.2, while boron oxide, B.sub.2 O.sub.3, a product of boric acid upon further dehydration, melts at about 460.degree. C. In another example, the sintering aid was made up of 8 w % (Ca,Cr) oxide, which has a eutectic point at about 1022.degree. C., and 6 w % B.sub.2 O.sub.3 and, because of the low melting point of B.sub.2 O.sub.3, the melting point of this sintering aid mixture would be expected to be very much lower than 1000.degree. C. A mixture of lanthanum chromite with the [B.sub.2 O.sub.3, (Ca,Cr) oxide] sintering aid was fired to about 90% of theoretical density at 1277.degree. C.

Thus, U.S. Pat. No. 4,749,632 teaches sintering of lanthanum chromite at low temperatures in air by the incorporation of relatively large quantities of compounds which melt at low temperatures and are referred to as sintering aids. However, the use of relatively large quantities of low-temperature melting compounds results in migration of some of the sintering aid ions into the adjacent layers during sintering thereby adversely affecting the sintering behavior and electrical performance of these layers. The large amounts of these sintering aids are deleterious to the fabrication and operational performance of the monolithic solid oxide fuel cell.

The need remains in the art for lanthanum chromite materials which sinter at lower temperatures (i.e. close to 1400.degree. C.) and which are especially suited for use in the monolithic solid oxide fuel cell.

SUMMARY OF THE INVENTION

This invention provides a lanthanum chromite powder mixture which sinters at temperatures of about 1400.degree. C. and which consists essentially of 1 mol of LaCr.sub.1-x M.sub.x O.sub.3, where M is a divalent metal selected from the group of zinc, copper and mixtures thereof and x ranges from 0.02 to 0.2, y mols of B.sub.2 O.sub.3, where y ranges from 0.0005 to 0.04, and z mols of La.sub.2 O.sub.3, where the ratio z/y ranges from 1 to 3. In addition, the invention process for preparing this powder mixture, and a ceramic obtained upon sintering the aforesaid powder mixture.

In one embodiment of the present invention there is provided a lanthanum chromite powder mixture which sinters at temperatures of about 1400.degree. C. in the presence of very small amounts of sintering aids. In particular, the amount of boron oxide used during sintering of this powder mixture is about one order of magnitude less than the amount used by Flandermeyer et al. (U.S. Pat. No. 4,749,632). In another embodiment, the invention provides a process for preparing the aforesaid powder mixture. Still another embodiment of the invention provides a ceramic which is obtained upon sintering a compact of the aforesaid powder mixture.

More specifically, the process embodiment of this invention comprises the steps of:

i. preparing a lanthanum chromite precursor powder having the empirical formula LaCr.sub.1-x M.sub.x O.sub.3 (Adsorbate) where M is a divalent metal selected from the group of zinc, copper or mixtures thereof, x ranges from 0.02 to 0.2, and Adsorbate is volatile matter which is adsorbed on the powder and which is present up to 35 weight percent based on total precursor weight, said precursor being prepared by: (a) reacting a solution containing a lanthanum compound and a chromium compound in an atomic ratio of La:Cr of 1:1-x with a stoichiometric excess of ammonium hydroxide to precipitate an intermediate hydroxide in the form of a slurry; (b) washing the precipitated intermediate hydroxide with a wash liquid comprising deionized (DI) water and DI water/alcohol mixtures to remove most of the anions from the lanthanum and chromium compounds used in step (a) and to yield a slurry in a water/alcohol liquid; (c) adding to the hydroxide slurry obtained in step (b) a solution of an M compound taken in such quantity as to yield an atomic ratio of La:Cr:M of 1:1-x:x where M is a divalent metal composed of zinc, copper and mixtures thereof and is operative as a dopant; (d) separating the powder from the liquid defined in step (b) at supercritical conditions, wherein temperature and pressure are equal to or greater than the critical point of the water/alcohol liquid in a batch or continuous process to obtain precursor lanthanum chromite powder having the empirical formula LaCr.sub.1-x M.sub.x O.sub.3 (Adsorbate); ii. calcining the lanthanum chromite precursor having the empirical formula LaCr.sub.1-x M.sub.x O.sub.3 (Adsorbate) at a temperature ranging from 650.degree. to 1100.degree. C. for a time period ranging from of 0.5 to 4 hours followed by deagglomeration to obtain sinter reactive lanthanum chromite ceramic powder having the chemical formula LaCr.sub.1-x M.sub.x O.sub.3 ; and iii. incorporating into the LaCr.sub.1-x M.sub.x O.sub.3 ceramic powder z mols of La.sub.2 O.sub.3 and y mols of B.sub.2 O.sub.3, where y ranges from 0.0005 to 0.04 mols per mol of LaCr.sub.1-x M.sub.x O.sub.3 and the ratio of z/y ranges from to 3.

In still another embodiment, this invention provides a ceramic product obtained by firing a powder mixture prepared in accordance with the aforementioned process. This lanthanum chromite powder mixture may be formed into powder compacts or components by any suitable method such as uniaxial pressing, cold isostatic pressing, slip-casting, die pressing, tape casting or calendering, and sintered in oxidizing or other atmospheres at a temperature ranging from about 1350.degree. to 1500.degree. C. to obtain dense lanthanum chromite with density higher than about 95% of theoretical density. The sintered product is a mixture of approximately 1 mol of LaCr.sub.1-x M.sub.x O.sub.3, where M is a divalent metal selected from the set consisting of zinc, copper or mixtures thereof and x ranges from 0.02 to 0.2, y mols of B.sub.2 O.sub.3, where y ranges from 0.0005 to 0.04, and z mols of La.sub.2 O.sub.3, where the ratio z/y is in the range of 1 to 3 or, preferably, in the range of 1.4 to 2.

DETAILED DESCRIPTION OF THE INVENTION

The powder mixture of the present invention has, as its principal component, lanthanum chromite. This lanthanum chromite is prepared from a lanthanum chromite precursor powder of extremely fine grain size.

The lanthanum chromite precursor powder is amorphous or microcrystalline and has the empirical formula LaCr.sub.1-x M.sub.x O.sub.3 (Adsorbate) where M is a divalent metal selected from the group of zinc, copper and mixtures thereof, x is in the range of 0.02 to 0.2, and Adsorbate is volatile matter which is adsorbed on the powder. The composition of the adsorbate is not precisely known, but consists essentially of water, alcohols and other organic adducts. The amount of the adsorbate present ranges up to about 35 weight percent of the total as-produced lanthanum chromite precursor.

The lanthanum chromite precursor is prepared by reacting a solution of lanthanum and chromium with a solution of ammonium hydroxide. It is necessary that the atomic ratio of lanthanum and chromium in the solution be the same as that of the precursor compound, that is 1:1-x. The liquid used to make the solutions may be DI water, organic solvents such as monohydric alcohols or their mixture. Any compounds of lanthanum and chromium may be used to make the solutions provided these compounds have sufficient solubility in the chosen solvent.

When the desired solvent is water, the compounds of lanthanum and chromium used to make the solutions may be, but are not limited to, chloride, nitrate, acetate, etc., salts. These salts include but are not limited to lanthanum chloride, lanthanum bromide, lanthanum nitrate, lanthanum acetate, chromium chloride, chromium bromide, chromium nitrate, chromium acetate. It is not necessary that the salts used in the preparation of the solution have a common anion.

An intermediate insoluble hydroxide with lanthanum and chromium in atomic ratio corresponding to that of the precursor or final lanthanum chromite, that is, ratio of 1:1-x is coprecipitated by mixing a solution of the desired compounds with a solution containing a stoichiometric excess of ammonium hydroxide. Precipitation of these metals at pH of 9 to 10 is essentially quantitative. The solution containing the metal salts is added to the solution of ammonium hydroxide under vigorous stirring or vice versa. However, addition of the metal salt solution to the hydroxide solution is the preferred method of mixing the solutions for coprecipitation. The metal salts may be dissolved in one solution or in separate solutions. In the case of separate metal solutions, the solutions should be added simultaneously, at the same location and the molar feed rates of the metals should correspond to the atomic ratio of the metals in the precursor and final lanthanum chromite.

The insoluble hydroxide intermediate, i.e., the coprecipitate formed from mixing the lanthanum and chromium solution with the ammonium hydroxide solution according to the method of the present invention, contains the lanthanum and chromium metals in the same atomic ratio as the final lanthanum chromite. This coprecipitate is voluminous, may be gelatinous, and, at high metal concentration, may turn into a rigid gel. However, it is preferred that the metal concentration be controlled at such levels that the precipitate forms a dispersion of high fluidity and this dispersion will be referred to as gel. In this context, the word gel is meant to denote a dispersion or slurry of precipitated or coprecipitated particles, which are aggregates of nanometer-size particles, in a liquid phase. The solids concentration and the viscosity of this dispersion are such that the gel flows relatively easily, is fairly stable, and can be pumped by any conventional slurry pump, such as a diaphragm pump.

The gel or slurry obtained from the coprecipitation step is then subjected to washings with deionized (DI) water, alcohols or mixtures thereof to remove the anions, that is, chlorides, bromides, nitrates or acetates from the lanthanum and chromium compounds used in the preparation of the hydroxide intermediate. This washing may be performed using batch or continuous processes. In a laboratory-scale batch process, the slurry is diluted with the appropriate wash liquid and stirred, and the precipitate is allowed to settle by gravity. The clear supernatant liquid containing the soluble anions is then decanted, and the wash process is repeated until the anion concentration is sufficiently low. Precipitates from halides, need to be washed thoroughly because residual halides in the final ceramic powder may degrade the powder's sintering behavior or mechanical properties. Thorough washing of nitrate or acetate anions is not necessary because residual amounts of such anions are easily removed during subsequent calcination steps. The composition of the wash liquid is progressively changed from DI water to alcohol in order to have the precipitate dispersed in a water/alcohol mixture with the concentration of water at about 20 w % or less at the end. Any alcohol may be used but monohydric alcohols with low molecular weight are preferred. Isopropanol, a widely used chemical solvent, is the most preferred alcohol.

To the slurry of the washed hydroxide gel is then added a solution of an M compound where M is a divalent metal such as zinc or copper and the compounds may be nitrate, acetate, or other soluble inorganic or organic salts which decompose at temperatures in the range of 200.degree. to 600.degree. C. The quantity of the M compound solution which is used should be such that the atomic ratio of the lanthanum and chromium in the hydroxide precipitate and M in the solution should be the same as the desired composition in the precursor or the final ceramic lanthanum chromite, that is, La:Cr:M should be equal to 1:1-x:x.

The water/alcohol slurry of the precipitated hydroxide and the dissolved M compound is then subjected to a supercritical separation. In other words, the powder is released from the liquid at temperature and pressure equal to or greater than the critical point of the water/alcohol liquid in a batch or continuous process. Under supercritical conditions the surface tension of the liquid is about zero, the solid particles are released from the liquid phase without compaction and, therefore, the powder is obtained in a highly divided state, i.e., the size of the particles is of the order of one nanometer. The powder which is produced from the supercritical separation is usually amorphous and retains adsorbed water and organic molecules. This powder is the precursor lanthanum chromite with empirical formula LaCr.sub.1-x M.sub.x O.sub.3 (Adsorbate) where Adsorbate is adsorbed volatile matter consisting of water, alcohols such as isopropanol, and other organic adducts whose composition is not precisely known.

Sinter-reactive lanthanum chromite powder with chemical formula LaCr.sub.1-x M.sub.x O.sub.3, where M is a divalent metal selected from the set of zinc, copper and mixtures thereof and x is in the range of 0.02 to 0.2, is prepared from the lanthanum chromite precursor which is produced according to the present invention as discussed hereandabove. To this end, the lanthanum chromite precursor powder is subjected to calcination in air to release adsorbed water and organic adducts and to crystallize the powder followed by deagglomeration of the calcined powder to reduce its particle size distribution.

In heating up the lanthanum chromite precursor in air the major weight loss of adsorbate usually occurs below 400.degree. C. with complete burn off at temperatures of about 550.degree. C. Calcination of the powder at about 550.degree. C. in air for 2 hours converts the amorphous powder to a crystalline material which is a mixture of lanthanum chromite, huttonite with chemical formula isostructural to LacrO.sub.4, and small amounts of lanthanum chromium oxide with chemical formula isostructural to La.sub.2 CrO.sub.6. On the other hand, calcination of the precursor powder at 750.degree. C. in air for 2 hours leads to the formation of perovskite lanthanum chromite with only trace quantities of huttonite (with chemical formula isostructural to LaCrO.sub.4) and lanthanum chromium oxide (with chemical formula isostructural to La.sub.2 CrO.sub.6) which completely disappear during densification. The calcination temperature and time are selected to tailor make the ceramic powder to suit the requirements of specific ceramic green forming processes. Generally, calcination of the lanthanum chromite precursor powder in the range of 650.degree. to 1100.degree. C. for 0.5 to 5 hours followed by deagglomeration yields lanthanum chromite powder with composition LaCr.sub.1-x M.sub.x O.sub.3 where M is zinc or copper and x is in the range of 0.02 to 0.2. This powder is very sinter-reactive and, under controlled atmospheres, powder compacts sinter to densities of at least 95% of theoretical at sintering temperatures as low as 1600.degree. C.

Although the sintering temperature of 1600.degree. C. for the powder of the present invention is lower than the temperatures required to sinter lanthanum chromite powders prepared by other state-of-the-art processes, this temperature is still higher than that desired for monolithic solid oxide fuel cell applications. It would be particularly advantageous if other means for further decreasing this temperature were available. Such means are provided, in accordance with the invention, by mixing the sinter-reactive powders of the present invention with small quantities of boric acid or boron oxide, B.sub.2 O.sub.3, and lanthanum oxide, La.sub.2 O.sub.3, where the molar ratio of La.sub.2 O.sub.3 to B.sub.2 O.sub.3 ranges from 1 to 3 (the atomic ratio of La to B is also the same), and preferably from 1.4 to 2. Lanthanum and boron oxide mixtures taken in the molar ratio of 1 to 3 have melting points in the range of 1311.degree. to about 1500.degree. C. [see FIG. 321 in Phase Diagrams for Ceramists, 3rd ed., (1974)] and, after firing, yield high melting, crystalline lanthanum borate compounds bind the mobile boron ions. Moreover, these crystalline compounds would prevent or inhibit the migration of boron ions into adjacent layers in the monolithic solid oxide fuel cell during operation. This, advantageously, contributes to the chemical and electrical stability of the fuel cell at operating temperatures.

The boron and lanthanum oxides are added to the lanthanum chromite as individual oxides or as prereacted lanthanum borates, or they are precipitated onto the lanthanum chromite powder by any suitable means. The mixing of lanthanum chromite with boron and lanthanum oxide or with lanthanum borate powders (La:B =1 to 3) is achieved by any powder mixing technique such as dry or wet ball-milling. Wet chemical techniques are used to mix lanthanum chromite with finely divided lanthanum and boron oxides. Lanthanum hydroxide is precipitated on chromite powder by adding ammonia to a suspension of lanthanum chromite powder in a liquid containing dissolved lanthanum nitrate. After removal of the nitrate anions from the suspension by washing, dissolved boron oxide is added to the suspension, which is then dried free of liquid. The lanthanum chromite powder containing boron and precipitated lanthanum compounds is then calcined at about 500.degree. C. to decompose residual nitrates and remove any volatile matter and to prereact the boron and lanthanum compounds with the surface of lanthanum chromite.

The resultant boron and lanthanum containing lanthanum chromite powder is then formed into powder compacts for firing. Powder compacts for sintering are formed by well known processes such as uniaxial pressing, cold isostatic pressing, extrusion, injection molding, roll pressing, tape casting and other ceramic forming techniques. Powder compacts containing small amounts of lanthanum and boron oxides, taken in the molar ratio of 1 to 3, and preferably in the ratio of 1.4 to 2, sinter to better than 97% of theoretical density when fired at about 1400.degree. C. in air for one (1) hour, and preferably at a temperature ranging from about 1350.degree. to 1500.degree. C. for a time period ranging from about 0.5 to 2 hours. Since these lanthanum chromite powder mixtures sinter to near full density in air at temperatures as low as 1400.degree. C., they facilitate the process of fabricating monolithic solid oxide fuel cells.

In order to more fully describe the advantages to be derived from the present invention, the following examples are set forth. These examples are considered illustrative only and are not intended to limit the scope and content of the invention as defined by the subjoined claims.

EXAMPLE 1

A six-gallon polyethylene container was loaded with four (4) liters of isopropanol (2-propanol) and one and one half (1.5) liters of concentrated ammonium hydroxide which typically contains 28-30 w % ammonia. This ammonia/water/isopropanol solution is denoted as solution A. In another container a solution of lanthanum nitrate and chromium nitrate was prepared by dissolving 450.7 grams of La(NO.sub.3).sub.3 .multidot.6H.sub.2 O and 374.8 grams of Cr(NO.sub.3).sub.3 .multidot.9H.sub.2 O in 7.5 liters of isopropanol and 0.4 liters of DI water. The resultant solution of lanthanum and chromium nitrates is denoted as solution B.

Solution B was added to solution A dropwise over a period of about 30 minutes under vigorous stirring with a shear mixer rotating at about 1500 revolutions per minute. A voluminous, greenish precipitate of lanthanum/chromium hydroxides formed instantaneously. This precipitate was kept well dispersed by maintaining the pH greater than about 9 (using excess ammonia) throughout the precipitation step and by the vigorous stirring. The latter also provided for uniform pH conditions and, therefore, instantaneous precipitation of the lanthanum/chromium hydroxides throughout this step.

The lanthanum/chromium hydroxide precipitate or gel was then subjected to several washes with DI water/isopropanol (15 volume percent DI water) mixtures by batch gravity settling methods to reduce the nitrate concentration to less than about 3 percent of its initial value.

To the washed hydroxide gel were added 30.96 grams of zinc nitrate hexahydrate (Zn(NO.sub.3).sub.2 .multidot.6H.sub.2 O) dissolved in one (1) liter isopropanol under rigorous stirring. The resultant gel was then subjected to solid/liquid separation using the continuous process described in U.S. Pat. No. 4,845,056 to obtain the lanthanum chromite precursor, LaCr.sub.0.9 Zn.sub.0.1 O.sub.3 (Adsorbate), powder. This precursor powder was amorphous and in a highly divided state as indicated by its high surface area (about 150 m.sup.2 /g).

EXAMPLE 2

The lanthanum chromite precursor powder, LaCr.sub.0.9 Zn.sub.0.1 O.sub.3.(Adsorbate), prepared as described in Example 1 was subjected to calcination in air at 800.degree. C. for 3 hours to yield a ceramic powder with surface area of 15 m.sup.2 /g. As a result of the calcination adsorbed water and organic adducts on the precursor powder were removed or burnt off and the precursor crystallized into zinc-doped lanthanum chromite having the nominal composition LaCr.sub.0.9 Zn.sub.0.1 O.sub.3.

EXAMPLE 3

A small quantity (about 1 gram) of the as-calcined powder from Example 2, zinc-doped lanthanum chromite LaCr.sub.0.9 Zn.sub.0.1 O.sub.3, was uniaxially pressed into a 12 mm diameter disk having a green density of 48.7% of theoretical. The disk was fired in air at 1400.degree. C. for 1 hour (14 hours to 1400.degree. C., 1 hour at 1400.degree. C., 7 hours to room temperature) and after firing was found to have a density of 82.6% of theoretical.

EXAMPLE 4

Precursor lanthanum chromite prepared according to the method described in Example 1 was calcined at 800.degree. C. for three (3) hours in air to yield ceramic powder of zinc-doped lanthanum chromite, LaCr.sub.0.9 Zn.sub.0.1 O.sub.3. The calcined powder was dry-ball milled for 4 hours to deagglomerate it.

Boric acid and lanthanum hydroxide were precipitated on small quantities of the LaCr.sub.0.9 Zn.sub.0.1 O.sub.3 according to the following procedure. 0.0044 g of B.sub.2 O.sub.3 and 0.109 g of La(NO.sub.3).sub.3 .multidot.6H.sub.2 O were dissolved in a solution consisting of 10 g of isopropanol and 2 g of water. To this solution there was added 6 g of LaCr.sub.0.9 Zn.sub.0.1 O.sub.3 under stirring to yield a suspension. Two (2) ml of concentrated ammonium hydroxide was then added dropwise to the suspension to precipitate lanthanum hydroxide and the resultant slurry was allowed to dry at ambient temperature. The dried powder was subsequently calcined at 550.degree. C. to remove residual nitrate and adsorbed water and isopropanol. The calcined product was a brown ceramic powder of LaCr.sub.0.9 Zn.sub.0.1 O.sub.3 containing the equivalent of 0.25 mol of B.sub.2 O.sub.3 and 0.50 mol of La.sub.2 O.sub.3 per I00 mols of zinc-doped lanthanum chromite as sintering aids. The exact chemical states of B.sub.2 O.sub.3 and of La.sub.2 O.sub.3 in the calcined powder are not known but are expected to be in the form of individual or complex oxides.

The same procedure was used to prepare two small batches of LaCr.sub.0.9 Zn.sub.0.1 O.sub.3, one containing the equivalents of 0.05 mol % of B.sub.2 O.sub.3 and 0.1 mol of La.sub.2 O.sub.3 per 100 mols of zinc-doped lanthanum chromite as sintering aids and the other 0.25 mol % B.sub.2 O.sub.3 and 0.25 mol % of La.sub.2 O.sub.3 per 100 mols of zinc-doped lanthanum chromite.

The calcined powders were used to make powder compacts by uniaxial pressing in a half inch die. These disks were then fired in air by ramping the furnace temperature at 100.degree. C./h to 1400.degree. C., holding at 1400.degree. C. for one (1) hour, and cooling to room temperature at 200.degree. C./h. Sintering results are shown in Table 1.

TABLE 1______________________________________Sintering of Zinc-dopedLanthanum Chromite with La.sub.2 O.sub.3 /B.sub.2 O.sub.3Chromite B.sub.2 O.sub.3 La.sub.2 O.sub.3 La.sub.2 O.sub.3 :B.sub.2 O.sub.3 Green* Fired*(mol) (mol) (mol) (mol:mol) Density Density______________________________________100 0.25 0.50 2 39.4 99100 0.25 0.50 2 44.1 100+100 0.25 0.25 1 39.3 99.1100 0.25 0.25 1 43.6 100+100 0.05 0.1 2 39.0 97.5100 0.05 0.1 2 44.0 100+______________________________________ *As % of theoretical density which is taken to be 6.65 g/ml The data of Table 1 show that Zinc-doped lanthanum chromite prepared according to the present invention sinters to full density at about 1400.degree. C./1 h in air in the presence of even small quantities of B.sub.2 O.sub.3 and La.sub.2 O.sub.3 sintering aids.

EXAMPLE 5

The lanthanum chromite precursor powder, LaCr.sub.0.9 Zn.sub.0.1 O.sub.3 (Adsorbate), prepared as described in Example 1 was subjected to calcination in air at 850.degree. C. for 3 hours to yield a ceramic powder with surface area of 4.5 m.sup.2 /g. As a result of the calcination adsorbed water and organic adducts on the precursor powder were removed or burnt off and the precursor crystallized into zinc-doped lanthanum chromite having the nominal composition LaCr.sub.0.9 Zn.sub.0.1 O.sub.3.

EXAMPLE 6

Precursor lanthanum chromite prepared according to the method described in Example 1 was calcined at 850.degree. C. for three (3) hours in air to yield ceramic powder of zinc-doped lanthanum chromite, LaCr.sub.0.9 Zn.sub.0.1 O.sub.3.

Boric acid and lanthanum hydroxide were precipitated on small quantities of the LaCr.sub.0.9 Zn.sub.0.1 O.sub.3 according to the following procedure. 0.0044 g of B.sub.2 O.sub.3 and 0.109 g of La(NO.sub.3).sub.3 .multidot.6H.sub.2 O were dissolved in a solution consisting of 10 g of isopropanol and 2 g of water. To this solution there was added 6 g of LaCr.sub.0.9 Zn.sub.0.1 O.sub.3 under stirring to yield a suspension. Two (2) ml of concentrated ammonium hydroxide was then added dropwise to the suspension to precipitate lanthanum hydroxide and the resultant slurry was allowed to dry at ambient temperature. The dried powder was subsequently calcined at 550.degree. C. to remove residual nitrate and adsorbed water and isopropanol. The calcined product was a brown ceramic powder of LaCr.sub.0.9 Zn.sub.0.1 O.sub.3 containing the equivalent of 0.25 mol of B.sub.2 O.sub.3 and 0.50 mol of La.sub.2 O.sub.3 per 100 mols of zinc-doped lanthanum chromite as sintering aids. The exact chemical states of B.sub.2 O.sub.3 and of La.sub.2 O.sub.3 in the calcined powder are not known but are expected to be in the form of individual or complex oxides.

The same procedure was used to prepare a small batch of LaCr.sub.0.9 Zn.sub.0.1 O.sub.3 containing the equivalent of 0.5 mol % of B.sub.2 O.sub.3 and 0.5 mol of La.sub.2 O.sub.3 per 100 mols of zinc-doped lanthanum chromite as sintering aids. The ratio of La.sub.2 O.sub.3 to B.sub.2 O.sub.3 or of La to B is equal to one in these powders and the composition of the sintering aids corresponds to LaBO.sub.3.

The calcined powders were used to make powder compacts by uniaxial pressing in a half inch die. These disks were then fired in air by ramping the furnace temperature at 100.degree. C./h to 1400.degree. C., holding at 1400.degree. C. for one (I) hour, and cooling to room temperature at 200.degree. C./h. Sintering results are shown in Table 2.

TABLE 2______________________________________Sintering of Zinc-dopedLanthanum Chromite with La.sub.2 O.sub.3 /B.sub.2 O.sub.3Chromite B.sub.2 O.sub.3 La.sub.2 O.sub.3 La.sub.2 O.sub.3 :B.sub.2 O.sub.3 Green* Fired*(mol) (mol) (mol) (mol:mol) Density Density______________________________________100 0.25 0.50 2 46.5 71.7100 0.50 0.50 1 45.4 93.5______________________________________ *As % of theoretical density which is taken to be 6.65 g/ml The data of Table 2 show that densification of zinc-doped lanthanum chromite at about 1400.degree. C./1 h in air is complete in the presence of even small quantities of B.sub.2 O.sub.3 and La.sub.2 O.sub.3.

An extremely high density was achieved in the sintering of lanthanum chromite powders at this very low temperature of about 1400.degree. C. in air. The density of 94.8% of theoretical obtained at 1400.degree. C. in air with the lanthanum chromite powder prepared according to the present invention is about the same as the density of 95.3% of theoretical obtained at 1740.degree. C. under inert atmosphere by Groupp and Anderson. Moreover, the density of 94.8% is only slightly lower than the density of about 98% of theoretical achieved at 1600.degree. C. for 2 hours in air according to the data of Hayashi et al., although those prior art workers pressed their disks to a green density of about 60% of theoretical, as compared to the 48.1% of theoretical employed in the present invention.

Having thus described the invention in rather full detail, it will be understood that such detail need not be strictly adhered to but that further changes may suggest themselves to one having ordinary skill in the art, all falling within the scope of the invention as defined by the subjoined claims.

Claims

1. A lanthanum chromite ceramic powder mixture which sinters at temperatures of about 1400.degree. C. and which consists essentially of 1 mol of LaCr.sub.1-x M.sub.x O.sub.3, where M is a divalent metal selected from the group of zinc, copper or mixtures thereof and x ranges from 0.02 to 0.2, y mols of B.sub.2 O.sub.3, where y ranges from 0.0005 to 0.04, and z mols of La.sub.2 O.sub.3, where the ratio z/y ranges from 1.4 to 2.

2. The product of claim 1 in which M is zinc.

3. The product of claim 1 in which M is copper.

4. A process for the preparation of a sinter-reactive lanthanum chromite precursor powder doped with a divalent metal and having the formula LaCr.sub.1-x M.sub.x O.sub.3, where M is the divalent metal and x ranges from about 0.02 to 0.2 said process comprising the steps of:

i. preparing a lanthanum chromite precursor powder having the empirical formula LaCr.sub.1-x M.sub.x O.sub.3 (Adsorbate) where M is selected from the group of zinc, copper or a mixture thereof, x ranges from 0.02 to 0.2, and Adsorbate is volatile matter, which is adsorbed on the powder and which is present up to 35 weight % based on total precursor weight, said precursor being prepared by:

(a) reacting a solution containing a lanthanum compound and a chromium compound in an atomic ratio of La:Cr of 1:1-x with a stoichiometric excess of ammonium hydroxide to precipitate an intermediate hydroxide in the form of a slurry;

(b) washing the precipitated intermediate hydroxide with a wash liquid comprising deionized (DI) water and DI water/alcohol mixtures to remove most of the anions from the lanthanum and chromium compounds used in step (a) and to yield a slurry in a water/alcohol liquid;

(c) adding to the hydroxide slurry obtained in step (b) a solution of an M compound taken in such quantity as to yield an atomic ratio of La:Cr:M of 1:1-x:x where M is a divalent metal comprised of zinc, copper and mixtures thereof and is operative as a dopant;

(d) separating the powder from the water/alcohol liquid at supercritical conditions, wherein temperature and pressure are equal to or greater than the critical point of the water/alcohol liquid in a batch or continuous process to obtain precursor lanthanum chromite powder having the empirical formula LaCr.sub.1-x M.sub.x O.sub.3 (Adsorbate);

ii. calcining the lanthanum chromite precursor having the empirical formula LaCr.sub.1-x M.sub.x O.sub.3 (Adsorbate) at a temperature ranging from 650.degree. to 1100.degree. C. for a time period ranging from 0.5 to 4 hours followed by deagglomeration to obtain sinter reactive lanthanum chromite ceramic powder having the chemical formula LaCr.sub.1-x M.sub.x O.sub.3 ; and

iii. incorporating into the LaCr.sub.1-x M.sub.x O.sub.3 ceramic powder z mols of La.sub.2 O.sub.3 and y mols of B.sub.2 O.sub.3, where y ranges from 0.0005 to 0.04 mols per mol of LaCr.sub.1-x M.sub.x O.sub.3 and the ratio of z/y ranges from 1 to 3.

5. The process of claim 4 in which said alcohol contains 1 to 5 carbon atoms.

6. The process of claim 4 in which said alcohol is isopropanol.

7. A sintered ceramic product produced from the ceramic powder of claim 1 by firing a powder compact at a temperature ranging from about 1400.degree. to 1500.degree. C. in air, said sintered product being a mixture of approximately 1 mol of LaCr.sub.1-x M.sub.x O.sub.3, where M is a divalent metal selected from the group of zinc, copper and mixtures thereof and x ranges from 0.02 to 0.2, y mols of B.sub.2 O.sub.3, where y ranges from 0.0005 to 0.04, and z mols of La.sub.2 O.sub.3, where the ratio z/y ranges from 1.4 to 2.

8. The product of claim 7 in which M is zinc.

9. The product of claim 7 in which M is copper.

10. The product of claim 7 wherein said firing step is carried out for a time period ranging from about 0.5 to 2 hours.