Brazing as a means of sealing ceramic membranes for use in advanced coal gasification processes

Coal is potentially a very inexpensive source of clean hydrogen fuel for use in fuel cells, turbines, and various process applications. To realize its potential however, efficient low-cost gas separation systems are needed to provide high purity oxygen that will enhance the coal gasification reaction and to extract hydrogen from the resulting gas product stream. Several types of inorganic membranes are being developed for hydrogen or oxygen separation, including porous alumina, transition metal oxide perovskites, and zirconia. Because they form the heart of the working device, numerous advances have been made in the fabrication and performance of these membrane materials. However, less emphasis has been placed on the materials that will be used in the balance of the device; in particular, the seals that bond the functional ceramic to the metallic structural component. In an effort to begin addressing this issue, we have examined ceramic-to-metal brazing as a method of sealing a model set of gas separation component materials: yttria-stabilized zirconia and stainless steel. In comparative high-temperature exposure testing of joints prepared using commercial brazes and a newly conceived braze alloy, the commercial material proved to be unsuitable due to excessive oxidation. On the other hand, the new material not only displayed superior oxidation resistance, but also excellent hermeticity in prototypic membrane testing.