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Solid oxide fuel cells (SOFC) hold great promise for clean power generation. However, high temperature stability and long term durability of the SOFC components have presented serious problems in SOFC technological advancement and commercialization. The seals of the fuel cells are the most challenging area to address. A high temperature gas seal is highly needed which is durable against cracking and gas leakage during thermal cycling and extended operation. This project investigates a novel composite seal by integrating 3D printed shape memory alloy (SMA) wires into a glass matrix. The SMA we use is TiNiHf and the glass matrix we use is SrO-La{sub 2}O{sub 3}-Al{sub 2}O{sub 3}-B{sub 2}O{sub 3}-SiO{sub 2} (SLABS). Dilatometry shows to be an extremely useful tool in providing the CTEs. It pinpoints regions of different CTEs under simulated SOFC thermal cycles for the same glass. For the studied SLABS glass system, the region with the greatest CTE mismatch between the glass seal and the adjacent components is 40-500 C, the typical heating and cooling regions for SOFCs. Even for low temperature SOFC development, this region is still present and needs to be addressed. We have demonstrated that the proposed SLABS glass has great potential in mitigating the thermal expansion mismatch issues that are limiting the operation life of SOFCs. TiNiHf alloy has been successfully synthesized with the desired particle size for the 3DP process. The TiNiHf SMA shape memory effect very desirably overlaps with the problematic low CTE region of the glass. This supports the design intent that the gradient structure transition, phase transformation toughening, and self-healing of the SMA can be utilized to mitigate/eliminate the seal problem. For the 3DP process, a new binder has been identified to match with the specific chemistry of the SMA particles. This enables us to directly print SMA particles. Neutron diffraction shows to be an extremely useful tool in providing information regarding the austenite to martensite phase transformation, SMA alloy lattice constant change, and the corresponding thermal stress from the glass matrix. It pinpoints regions of SMA phase transformation and the thermal stress effect under simulated SOFC thermal cycles. The bilayer test shows that there is still much work to be done for the proper integration of the seal components. Large scale production should lower the cost associated with the proposed approach, especially on the raw material cost and 3D printing

Digital Manufacturing of Gradient Meshed SOFC Sealing Composites with Self-Healing Capabilities