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Understanding Drop-on-Demand Inkjet Process Characteristics in the Application of Printing Micro Solid Oxide Fuel Cells

Hill, Theresa Y.
http://orcid.org/0000-0002-0660-5137
http://rave.ohiolink.edu/etdc/view?acc_num=wright156167105938597

Abstract Details

2019, Doctor of Philosophy (PhD), Wright State University, Engineering PhD.
Drop on demand (DOD) inkjet printing has been widely investigated for its low cost, noncontact, high throughput, and reproducible process advantages. This dissertation research sought to capitalize on these advantages for use in micro solid oxide fuel cells (micro SOFCs). Understanding the important variables underpinning the inkjet process, including ink formulation, jet kinematics, and process settings was essential. These variables were evaluated for their impact on drop deposition quality, resolution, microstructure, and electrochemical functionality, with the end goal of making submicron to micron scale ceramic features. Initially, the fluid kinematics of single pass printing was investigated using a dilute, solid-solvent, colloidal, ink suspension of of La0.6Sr0.4Fe0.8Co0.2O3 (LSFC) and α-terpineol. Favorable process conditions were identified that attained uniform, well-shaped, circular dots ~ 0.1 μm thick and ~ 80 μm in diameter. Multiple, sequential ink passes were employed to increase feature dimensions on the x/y/z axes. This required additional process constraints to control deposition quality and resolution of micro features including micro-dots (0-D), micro-lines (1-D) and micro-planes (2-D). Using optimal conditions, 0-D dots and 1-D lines with x/y dimensions < 100 μm and z axis dimensions < 1 μm with dense, open or networked microstructures were demonstrated; in addition 2-D planes having smooth surface and continuous intra-planar ceramic coverage with dimensions as small as ~ 100 μm by ~ 100 μm were achieved. Sintering the inkjetted submicron prototypes produced consolidated submicron films that were uniform, smooth and void of defects such as cracks or delamination. Thermal treatments resulted in grain growth from an average crystallite size of ~158 nm to ~ 356 nm. Heat treatments < 800°C were essential to avoid deleterious effects on electrochemical activity. Electrochemical characterizations of prototypes produced tolerable peak power density of 0.08 mW/cm2 at 400°C, indicating for the first time ever that inkjet printing can produce a working micro SOFC. Additional tuning of the 2-D plane inkjet variables and heat treatment regimen, which affect conductivity, kinetics and gas diffusion properties, improves performance significantly. This research has shown that inkjet processing can rapidly engineer quality submicron ceramic features, thus facilitating investigations such as high throughput screening studies to more rapidly advance micro SOFC technology, a feat not possible with the current processing routes. The knowledge gained from this research may be useful in other micro all-solid energy conversion and storage systems, similarly decreasing the barriers for innovation of power generation technologies.
Hong Huang, Ph.D. (Advisor)
Sharmila Mukhopadhyay, Ph.D. (Committee Member)
Jason Deibel, Ph.D. (Committee Member)
Lei Kerr, Ph.D. (Committee Member)
Thomas Reitz, Ph.D. (Committee Member)
167 p.
Engineering; Materials Science
inkjet printing; micro pattern; solid oxide fuel cell; LSFC; ink formulation; colloidal suspension; cathode; coffee ring effect; fluid mechanics; Weber number; catalytic activity; deposition; thin films; thermal treatment; MEMs; ALD

Recommended Citations

Citations

  • Hill, T. Y. (2019). Understanding Drop-on-Demand Inkjet Process Characteristics in the Application of Printing Micro Solid Oxide Fuel Cells [Doctoral dissertation, Wright State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=wright156167105938597

    APA Style (7th edition)

  • Hill, Theresa. Understanding Drop-on-Demand Inkjet Process Characteristics in the Application of Printing Micro Solid Oxide Fuel Cells. 2019. Wright State University, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=wright156167105938597.

    MLA Style (8th edition)

  • Hill, Theresa. "Understanding Drop-on-Demand Inkjet Process Characteristics in the Application of Printing Micro Solid Oxide Fuel Cells." Doctoral dissertation, Wright State University, 2019. http://rave.ohiolink.edu/etdc/view?acc_num=wright156167105938597

    Chicago Manual of Style (17th edition)

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This open access ETD is published by Wright State University and OhioLINK.