Dense metal membrane fabrication method

Thicker, self-supporting, dense metal membranes are known. These are tubular and are usually commercially successful palladium-silver hydrogen separation membranes were of this type.21 Currently, Power and Energy, Inc. also fabricates this type of membrane, although planar membranes are more common due to easier fabrication and a greater variety of fabrication methods. 

SEM photographs of sputtered films show that the layers are fairly dense and appear to crack into platelets when subjected to MEA fabrication. The dense films do not lend themselves to high surface areas therefore, there is substantial scope for enhancement of performance if the surface area can be increased. This may be achieved by producing porous 3-D Pt-Ru layered structures. One such method for creating such 3-D structures, that seem to be extremely promising, involves the pre-treatment of the membrane surface by ion-beam etching, which is then followed by sputter-deposition of the metal. This results in substantially enhanced surface area and very rough nanostructures. Next year s effort will include characterization of such films. 

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