Methods of forming near-net shape structures from non-stoichiometric oxides
AssigneeBattelle Energy Alliance, LLC
InventorsPrabhat K. Tripathy, Michael R. Shaltry
Life of this patent
Estimating the term…
Abstract
A method of forming a near-net shape structure comprises forming a structure comprising non-stoichiometric metal oxide comprising at least one metal and less than a stoichiometric amount of oxygen, and electrochemically reducing the non-stoichiometric metal oxide in an electrochemical cell to form a structure having a near-net shape and comprising the at least one metal having less than about 1,500 ppm oxygen. Related methods of forming a non-stoichiometric metal oxide by sintering, annealing, or additive manufacturing, and forming a near-net shape structure from the non-stoichiometric metal oxide, as well as related electrochemical cells are also disclosed.
Claims23
A method of forming a near-net shape structure, the method comprising:
- sintering a green structure exhibiting a green structure shape and comprising a stoichiometric metal oxide in a reducing atmosphere to form a structure comprising a non-stoichiometric metal oxide comprising at least one metal and less than a stoichiometric amount of oxygen;
- and
- after sintering the green structure to form the structure comprising the non-stoichiometric metal oxide, electrochemically reducing the non-stoichiometric metal oxide in an electrochemical cell to form a near-net shape structure comprising the at least one metal and having less than about 1,500 ppm oxygen, wherein the near-net shape structure has a shape substantially corresponding to the green structure shape.
A method of forming a near-net shape structure, the method comprising:
- forming a green structure comprising at least one stoichiometric metal oxide;
- sintering the green structure in the presence of at least one reducing gas to reduce the at least one stoichiometric metal oxide of the green structure and to form a non-stoichiometric metal oxide;
- and
- reducing the non-stoichiometric metal oxide in an electrochemical cell including a cathode comprising the non-stoichiometric metal oxide to form a structure having a near-net shape and comprising an elemental metal or a metal alloy.
A method of forming a near-net shape structure, the method comprising:
- forming a structure comprising an oxygen deficient non-stoichiometric metal oxide in a reducing environment, the non-stoichiometric metal oxide comprising less than a stoichiometric amount of oxygen and at least one metal, wherein the structure comprising the oxygen deficient non-stoichiometric metal oxide consists essentially of the non-stoichiometric metal oxide;
- and
- after forming the non-stoichiometric metal oxide, electrochemically reducing the non-stoichiometric metal oxide in an electrochemical cell to form the near-net shape structure.
Dependencies are inferred from the claim text.