Development of high energy density dielectrics with low temperature coefficients of capacitance that are systems integrable are needed for extreme environment, defense and automotive applications. The synthesis of high purity chemically prepared Ca(Zr,Ti)O3 powders is described and has resulted in the lowering of conventional firing temperatures by over 100 C. Direct write aerosol spray deposition techniques have been used to fabricate high quality single layer and multilayer capacitors from these powders. The dielectric constants of the direct write capacitors are equivalent to those of fired bulk ceramics. Our presentation emphasizes the synthesis, phase evolution and microstructure development that has resulted in dielectrics with energy densities in excess of 3 J/cm3 with less than 1% change in dielectric constant over a 200 C temperature range.
Fine powders of calcium zirconate (CaZrO{sub 3}, CZ) and calcium titanate (CaTiO{sub 3}, CT) were synthesized using a nonaqueous oxalate co-precipitation route from Ca(NO{sub 3}){sub 2}{center_dot}4 H{sub 2}O and group(IV) n-butoxides (Ti(OBu{sup n}){sub 4} or Zr(OBu{sup n}){sub 4}). Several reaction conditions and batch sizes (2-35 g) were explored to determine their influence on final particle size, morphology, and phase. Characterization of the as-prepared oxalate precursors, oven dried oxalate precursors (60-90 C), and calcined powders (635-900 C) were analyzed with TGA/DTA, XRD, TEM, and SEM. Densification and sintering studies on pressed CZ pellets at 1375 and 1400 C were also performed. Through the developed oxalate co-precipitation route, densification temperatures for CZ were lowered by 125 C from the 1500 C firing temperature required for conventional mixed oxide powders. Low field electrical tests of the CZ pellets indicated excellent dielectric properties with dielectric constants of {approx}30 and a dissipation factor of 0.0004 were measured at 1 kHz.
An environmentally friendly method and materials study for desalinating inland brackish waters (i.e., coal bed methane produced waters) using a set of ion-exchange materials is presented. This desalination process effectively removes anions and cations in separate steps with minimal caustic waste generation. The anion-exchange material, hydrotalcite (HTC), exhibits an ion-exchange capacity (IEC) of {approx} 3 mequiv g{sup -1}. The cation-exchange material, an amorphous aluminosilicate permutite-like material, (Na{sub x+2y}Al{sub x}Si{sub 1-x}O{sub 2+y}), has an IEC of {approx}2.5 mequiv g{sup -1}. These ion-exchange materials were studied and optimized because of their specific ion-exchange capacity for the ions of interest and their ability to function in the temperature and pH regions necessary for cost and energy effectiveness. Room temperature, minimum pressure column studies (once-pass through) on simulant brackish water (total dissolved solids (TDS) = 2222 ppm) resulted in water containing TDS = 25 ppm. A second once-pass through column study on actual produced water (TDS = {approx}11,000) with a high carbonate concentration used an additional lime softening step and resulted in a decreased TDS of 600 ppm.
Niobium doped PZT 95/5 (lead zirconate-lead titanate) is the material used in voltage bars for all ferroelectric neutron generator power supplies. In June of 1999, the transfer and scale-up of the Sandia Process from Department 1846 to Department 14192 was initiated. The laboratory-scale process of 1.6 kg has been successfully scaled to a production batch quantity of 10 kg. This report documents efforts to characterize and optimize the production-scale process utilizing Design of Experiments methodology. Of the 34 factors identified in the powder preparation sub-process, 11 were initially selected for the screening design. Additional experiments and safety analysis subsequently reduced the screening design to six factors. Three of the six factors (Milling Time, Media Size, and Pyrolysis Air Flow) were identified as statistically significant for one or more responses and were further investigated through a full factorial interaction design. Analysis of the interaction design resulted in developing models for Powder Bulk Density, Powder Tap Density, and +20 Mesh Fraction. Subsequent batches validated the models. The initial baseline powder preparation conditions were modified, resulting in improved powder yield by significantly reducing the +20 mesh waste fraction. Response variation analysis indicated additional investigation of the powder preparation sub-process steps was necessary to identify and reduce the sources of variation to further optimize the process.
The Materials Chemistry Department 1846 has developed a lab-scale chem-prep process for the synthesis of PNZT 95/5, referred to as the ''SP'' process (Sandia Process). This process (TSP) has been successfully transferred to and scaled-up by Department 14192 (Ceramics and Glass Department), producing the larger quantities of PZT powder required to meet the future supply needs of Sandia for neutron generator production. The particle size distributions of TSP powders routinely have been found to contain a large particle size fraction that was absent in development (SP) powders. This SAND report documents experimental studies focused on characterizing these particles and assessing their potential impact on material performance. To characterize these larger particles, fractionation of several TSP powders was performed. The ''large particle size fractions'' obtained were characterized by particle size analysis, SEM, and ICP analysis and incorporated into compacts and sintered. Large particles were found to be very similar in structure and composition as the bulk of the powder. Studies showed that the large-size fractions of the powders behave similarly to the non-fractionated powder with respect to the types of microstructural features once sintered. Powders were also compared that were prepared using different post-synthesis processing (i.e. differences in precipitate drying). Results showed that these powders contained different amounts and sizes of porous inclusions when sintered. How this affects the functional performance of the PZT 95/5 material is the subject of future investigations.
The Materials Chemistry Department 1846 has developed a lab-scale chem-prep process for the synthesis of PNZT 95/5, a ferroelectric material that is used in neutron generator power supplies. This process (Sandia Process, or SP) has been successfully transferred to and scaled by Department 14192 (Ceramics and Glass Department), (Transferred Sandia Process, or TSP), to meet the future supply needs of Sandia for its neutron generator production responsibilities. In going from the development-size SP batch (1.6 kg/batch) to the production-scale TSP powder batch size (10 kg/batch), it was important that it be determined if the scaling process caused any ''performance-critical'' changes in the PNZT 95/5 being produced. One area where a difference was found was in the particle size distributions of the calcined PNZT powders. Documented in this SAND report are the results of an experimental study to determine the origin of the differences in the particle size distribution of the SP and TSP powders.