Powdered starting material for a nickel-based alloy for manufacturing a porous anode of a fuel cell, method producing such a material, method for manufacturing an anode for fuel cells, the anode obtained and also a fuel cell which contains such an anode

Abstract: The invention provides a powdered starting material for a nickel-based alloy for manufacturing a porous anode of a fuel cell containing 0.5 to 10% by weight of aluminium, titanium and/or zirconium. The powder is manufactured using a mixture of carbonyl nickel powder and a powder of an intermetallic aluminium, titanium and/or zirconium compound having a particle size of 1 to 10 microns. The powder is produced by mixing the carbonyl nickel powder with an amount of an intermetallic compound such that 0.5 to 10% by weight of the desired element or elements is present in the anode material, the intermetallic compound having a particle size of 1 to 10 mm. An anode for a fuel cell can be produced from the powder by applying the powder to a substrate and sintering it at 900 to 1100°C.

Description: The invention relates to a powdered starting material according to the preamble of claim 1 as well as a method for producing a powdered starting material according to the preamble of claim 2. Such a material and method are known from the European patent application 0,259,226, which describes a powdered nickel-based alloy in which the particles size is 3 to 30 micro-meters. Said powder is preferably formed by water atomization, the water injection pressure being 400 kg/cm² and 0.02 to 2 m³ of water being used per kg of powder. Until a short time ago, the most generally used method for manufacturing an anode for molten carbonate fuel cells was to mix carbonyl-nickel powder with 1 to 10% by weight of chromium powder. Tapes of said powder mixture were cast on a flat base and said tapes were sintered. Another common method is to cast and sinter tapes from 100% carbonyl-nickel powder and then immerse them in an aqueous solution of Cr(NO₃)₂, followed by drying and heat treatment. In both methods it is desirable that use is made of carbonyl-nickel powder which: a) gives a very attractive structure in the anode material with the desired pore size because the nickel powder has a special chain structure of primary particles having a size of approximately 3 micrometers, b) has a very attractive price. A disadvantage is, however, that the anode material containing 1-10% by weight of chromium exhibits too much creep during operation in the cell at fairly high temperature (650-700°c), as a result of which the material undergoes much shrinkage and, in particular, the thickness decreases considerably under the influence of a vertically applied loading of 2-4 kg/cm². (Such a loading usally occurs as a result of the structure of the cells.) This results in decreasing cell performances during a prolonged period of service. It is known that the creep properties of anode material composed of nickel containing 0. 5-10% by weight of aluminium are appreciably better in molten carbonate fuel cells. A possible method of manufacturing these anodes would be to mix nickel powder with 0.5-10% by weight of aluminium powder of approximately the same particle fineness as the nickel powder and to use this mixture in casting tapes and sintering. However, the melting point of aluminium is 660°C, whereas the sintering is carried out at 900 to 1100°C. This results in premature melting of the Al with exothermic reactions between aluminium and nickel as the consequence. Said reactions cannot practically be controlled and several aluminium nickel compounds will be formed, that can completely destroy the structure present by the formation of relatively large agglomerates with an undesired pore structure. In addition, Al having the desired fine particle size of 3 micrometers of less is so susceptible to O₂ absorbtion that this powder and the mixtures thereof can be used only under O₂-free conditions, and this would have a considerable cost-increasing effect. A second possible way of manufacturing anodes containing 0.5-10% by weight of Al is by making use of powders having the desired composition which are produced by atomising. This may be by water atomising (1) or by gas atomising. Disadvantages of this method are: a) The powders obtained by atomising are expensive, especially if fine powders having a particle size of approximately 3 micrometers are necessary. b) The particle shape of these powders approximates more to a round shape, whereas carbonyl nickel has more of a chain structure. The round particles are considerably disadvantageous for the desired anode structure. A starting material of the type described in the preamble of claim 1 has now been found which is characterised in that it is manufactured using a mixture of a carbonyl-nickel powder and a powder of an intermetallic compound of nickel and aluminium, titanium and/or zirconium having a particle size of 1-10 micrometers. In this case intermetallic compounds having a melting point higher than the sintering temperature of the mixed powders are used. The percentage by weight of said intermetallic compounds which are used is so chosen that 0.5 to 10% by weight of the desired element or elements (Al, Ti and/or Zr) is present in the anode material. The invention therefore also provides a method for producing this material which is characterised in that the carbonyl-nickel powder is mixed with an amount of the intermetallic compound which is such that 0.5 to 10% by weight of said desired element or elements is present in the anode material, the intermetallic compound having a particle size of 1 to 10 micrometers and a melting point higher than the sintering temperature of the mixed powders. By applying a powder according to the invention to a substrate and sintering in a suitable manner at a temperature of 900 to 1100°C, an anode can be manufactured for fuel cells. The anode materials obtained can be used in a manner known per se in fuel cells and are very effective in them. In said method and in said powdered starting material suitable intermetallic compounds are NiAl, Ni₂Al₃, NiAl₃, NiTi, NiTi₂, NiZr and NiZr₂. Intermetallic compounds have a brittle nature and can therefore readily and cheaply be ground to form small particle sizes. In order, therefore, to manufacture anodes containing 0.5 to 10% by weight of Al in the nickel, the intermetallic compound NiAl, for example, is ground to a particle size of less than 10 micrometers, average particle size approximately 3 micrometers. Enough fine NiAl powder is now mixed with carbonyl-nickel powder that the desired percentage by weight of Al is achieved in the mixture. In order, for example, to achieve 5% by weight of Al in the mixture, 15.88% by weight of NiAl is added to the carbonyl nickel. The invention offers the following advantages: a) The attractive carbonyl-nickel powder can be used, b) the intermetallic compound added can be added in virtually any desired particle size, c) because the aluminium is now bound to a second element, it is less inclined to absorb oxygen, d) at 1638°C, the melting point of, for example, nickel-aluminium is far above the temperature at which the tapes are sintered (approximately 900 to 1100°C), as a result of which only well controlled solid state reactions occur during the sintering of the anode. As a result of this, an attractive anode structure is obtained. Intermetallic compounds with their melting points are: NiAl Ni₂Al₃ NiAl₃ NiTi NiTi₂ NiZr NiZr₂ 1638°C 1550°C 1100°C 1310°C 1000°C 1260°C 1120°C e) as the aluminium diffuses out of the NiAl into the carbonyl nickel during the sintering process, the melting point of the NiAl will not drop below 1385°C. This is therefore still well above the sintering temperature. The same applies, of course, to the other intermetallic compounds mentioned. Example I A powdered starting material was prepared by mixing carbonyl-nickel powder having an average particle size of 2.9 micrometers with an amount of NiAl such that the mixture contained 15.88% by weight of NiAl. (Average particle size of the NiAl 5.9 micrometers). This mixture was used to manufacture anode material sintered on in the form of approximately 1 mm thick sheet material with the aid of the so-called "tape casting" procedure. Some of said sheet material measuring 40 x 100mm was sintered at 1000°C under a reducing atmosphere (75% N₂ + 25% H₂) for thirty minutes on a supporting base of aluminium oxide. After the sintering it was determined with a microprobe that 90% of the aluminium present had diffunded into the nickel. This was further confirmed by an X-ray diffraction test. This small sintered plate was removed from the supporting base and a small plate having a diameter of 19.4 mm taken therefrom was used as anode material in a molten carbonate fuel cell. During the test period of 5,000 hours with a loading of 150 milliamperes per cm², the cell potential dropped from 925 millivolts to 920 millivolts, a drop therefore of 5 millivolts. Under comparable conditions, the cell potential certainly drops 25 millivolts if an Ni-10% by weight chromium anode is used. (known from experience). For a target fuel cell service life of 40,000 hours and an initial potential of 925 millivolts, this means, in the final phase, a potential under a load of 885 millivolts for the NiAl anode and of 725 millivolts for the NiCr anode. An attractive difference therefore in the advantage of the NiAl anode.

Claims: Powdered starting material for a nickel-based alloy for manufacturing a porous anode of a fuel cell, which contains 0.5 to 10% by weight of aluminium, titanium and/or zirconium, characterised in that it is manufactured using a mixture of carbonyl-nickel powder and a powder of an intermetallic compound of nickel and aluminium, titanium and/or zirconium having a melting point higher than the sintering temperature of the mixed powders and a particle size of 1-10 micro meters. Method for producing a powdered starting material for producing a nickel based alloy for manufacturing an anode for a fuel cell, characterised in that carbonyl-nickel powder is mixed with an amount of an intermetallic compound comprising nickel and at least one element selected from aluminium, titanium and/or zirconium such that 0.5 to 10% by weight of the desired element or elements is present in the anode material, the intermetallic compound having a melting point higher than the sintering temperature of the mixed powders and a particle size of 1-10 micro meters. Method according to Claim 2, characterised in that NiAl, Ni₂Al₃, NiAl₃ NiTi, NiTi₂, NiZr and/or NiZr₂ is used as the intermetallic compound. Method according to Claim 3, characterised in that NiAl, Ni₂Al₃ and/or NiAl₃ is used. Method for manufacturing an anode for a fuel cell, characterised in that a powder according to Claim 1 or obtained according to Claims 2-4 is applied to a substrate and sintered at 900-1100°C. Anode obtained according to Claim 5. Fuel cell, characterised in that it contains an anode obtainable according to Claim 5 or an anode according to Claim 6.

Inventors: VAN BEIJNEN CHRISTIANUS ANTONI, VAN DER MOLEN SYTZE BERNHARD, VAN BEIJNEN, CHRISTIANUS ANTONIUS MARIA, VAN DER MOLEN, SYTZE BERNHARD
Applicants: STICHTING ENERGIE, STICHTING ENERGIEONDERZOEK CENTRUM NEDERLAND(ECN)
Application year: 1991
Main classification: C22C1
IPC codes: H01M4, C22C1, H01M8, B22F5