Ceramic cost-effective technique

In the last few decades, polymeric materials have found many applications and govern a major part of our day-to-day life. The polymeric materials are strong, lightweight, and easily processable with cost-effective techniques [1]. However, the properties of the pure polymeric materials limit their application in diversified fields. The introduction of filler materials into the polymer matrix generates properties superior to those of individual components. The combination forms a single system the polymer nanocomposites exhibit improved strength, stiffness and dimensional stability with adequate physical properties compared to pure ploymer. These nanocomposites can be of different types such as ceramic-based nanocomposites, fiber-reinforced nanocomposites, polymer-clay nanocomposites, etc. 

Vogel et al [223] describes the successful development by Dornier of a cost-effective technique for producing fiber reinforced ceramics and are able to manufacture complex shapes and integrated structures. Carbon fiber reinforced SiC has the required damage tolerant fracture behavior and sufficient reliability with marked weight reduction and... 

Nowadays, the conversion treatment is being abandoned in favor of other processes, due to its health problems for humans, as a result of the formation of hexavalent chromium as a by-product of the treatment [5]. In particular, ceramic coatings fabricated through the sol-gel route are becoming relevant because they are environmentally friendly and it is a cost-effective technique that is easy to commercialize [6,7]. 

Traditional ceramics are usually based on clay and silica. There is sometimes a tendency to equate traditional ceramics with low technology, however, advanced manufacturing techniques are often used. Competition among producers has caused processing to become more efficient and cost effective. Complex tooling and machinery is often used and may be coupled with computer-assisted process control. 

The plasma spray technique offers a straightforward and cost-effective means to spray deposits of metals and ceramics that are tens to hundreds of micrometers in thickness onto a variety of substrates in applications involving thermal-barrier or insulator coatings. Typical plasma-spray deposits are porous, with only 85-90% of theoretical density. 

The technique of spray pyrolysis can be used to obtain both, dense or porous oxide films, and to produce ceramic coatings and powders. Compared to other deposition techniques, spray pyrolysis is a simple method for operational control. It is also cost-effective, especially regarding the cost of system implementation. Furthermore, deposition in multi-layers can be easily obtained by this versatile technique. 

In the continuing effort to improve the quality of ceramic powders, preferred characteristics include small and uniform particle size (<1.0 pm) and a nonagglomerated state of dispersion. Several attempts have been reported involving chemical techniques that produce ceramic powders with nanosize particles (1-7). These chemical techniques have been shown to be advantageous by eliminating the need for high temperature calcination reactions and milling procedures to achieve fine particle sizes. Processes that produce the final powder at low temperature and fast reaction time result in a more cost effective material. 

A metal-supported cell and stack concept is ideally based upon a low-cost stainless steel cell support and low-cost stainless steel thin metallic sheet interconnect bonded together with a cost-effective metalfic brazing or welding technique. The concept substimtes brittle ceramics with ductile metallic components and thereby to achieve a desirable, graceful non-catastrophic failure mode of the cells and stacks. The main issue addressed in the development of this concept is the simultaneous achievement of robustness, rehabUity and cost-effectiveness offered by the metalfic materials as well as the high electrochemical performance offered by next generation electrode development based on nano-structured materials. 

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