PNNL

Abstract

A novel hybrid compressive mica seal was developed that showed an exceptionally low leak rate of ~8.9x10-4 sccm/cm at 800 degrees C and a compressive stress of 100 psi, about 740 times lower than that of the conventional compressive mica seals (6.6x10-1 sccm/cm), at a pressure gradient of 2 psi. The hybrid compressive mica seals are composed of two compliant metallic layers and a mica layer. Three commercially available micas were tested in this study. All showed substantial improvements in reducing the leak rates by using the hybrid design. The best results were obtained using Muscovite single crystal mica and 5 mil silver layers. Using the paper-form of Muscovite and Phlogopite mica, the leak rates were still far superior (~1x10-1 sccm/cm) compared to mica without the compliant silver layer (about 6~9 sccm/cm). The microstructure of the mica was examined before and after the 800 degrees C leak tests. These results were also compared with results for hybrid seals using glass interlayers. In addition, an explanation for the substantial reduction of the leak rates was proposed, and the application of the hybrid compressive mica seals in planar SOFC stacks was briefly addressed.