Powder aerosol deposition method — novel applications in the field of sensing and energy technology

Abstract

The Aerosol Deposition (AD) method is a dry spray coating process for the production of dense ceramic coatings at room temperature directly from the ceramic raw powder. In order to avoid confusion with liquid aerosol technology, the term powder aerosol deposition (PAD) is introduced here, to highlight that the aerosol consists only of ceramic powder and carrier gas. Especially in the field of functional ceramics, PAD is a promising alternative to conventional sinter-based production processes. This review focuses on the PAD of functional ceramics in the field of sensing and energy technology. In this context, especially current developments and trends are presented. On the part of the sensors, gas and temperature sensors are especially considered, whereas in the field of energy technology, the focus is on vibration energy harvesting, thermoelectric generators, superconductors, and solar cells as well as on all solid-state batteries and fuel cells. Besides the different applications of PAD films, this review also highlights opportunities for influencing the film properties by the used powder or the process parameters.

What Happens during Thermal Post‐Treatment of Powder Aerosol Deposited Functional Ceramic Films? Explanations Based on an Experiment‐Enhanced Literature Survey

“…[ 11 ] Additionally, Schubert et al recently published a comprehensive review article on PAD films with a focus on functional ceramics in the field of sensing and energy technology. [ 29 ]…”

“…[11] Additionally, Schubert et al recently published a comprehensive review article on PAD films with a focus on functional ceramics in the field of sensing and energy technology. [29] Many new research fields for PAD films emerged in the recent years, like colored luminescent films [73] and more exotic applications like protective films of lunar regolith for the In Situ Resource Utilization (ISRU) mission from the European Space Agency (ESA) [34] or even martian regolith, [74,75] as well as ceramic brushite films for dental brackets. [76] While for these applications, the film properties are already sufficient in their as-deposited state, many other applications with electrical or magnetic functionality exhibit decreased functional properties for PAD films in the as-deposited state.…”

“…Only a dry carrier gas supply (i.e., air, oxygen, nitrogen, or noble gases) for the generation and acceleration of the aerosol is necessary, combined with a rough vacuum of around 1 mbar in the deposition chamber. The commonly used name “aerosol deposition method” (abbreviated as ADM or AD) was embossed by Akedo in the late 1990s; [ 23,24 ] however, several related terms such as vacuum kinetic spray (VKS), [ 25 ] vacuum cold spray (VCS), [ 26 ] nanoparticle deposition system (NPDS), [ 27 ] granule spray in vacuum (GSV), [ 28 ] and powder aerosol deposition (PAD) [ 29 ] are used synonymously by different research groups. To emphasize on the fact, that the deposition takes place by just spraying the dry raw ceramic powder, we prefer the term powder aerosol deposition and its abbreviation PAD, which is therefore used in this manuscript.…”

Laser‐Annealing of Thermoelectric CuFe0.98Sn0.02O2 Films Produced by Powder Aerosol Deposition Method

“…[ 1 ] Due to the worldwide development of this process method, different names like aerosol deposition (AD), [ 2 ] vacuum kinetic spray (VKS), [ 3 ] vacuum cold spray (VCS), [ 4 ] granule spray in vacuum (GSV), or nanoparticle deposition system (NPDS) [ 5 ] are used by different research groups. The variety of suitable ceramics ranges from insulator materials like Al 2 O 3, [ 6 ] dielectric materials like BaTiO 3 and Bi 4 Ti 3 O 12 , [ 7 ] solid electrolytes for proton conducting fuel cells like Ba(Zr, Sn, Ce)O 3 , [ 8–10 ] all‐solid‐state battery electrolytes like Li 7 La 3 Zr 2 O 12 , [ 11 ] sensor materials [ 12 ] and lunar regolith [ 13,14 ] for futuristic applications in space to thermoelectric films like CuFeO 2 . [ 15 ] Thermoelectric materials enable the direct emission‐free conversion of thermal to electrical energy and vice versa.…”

Recent Advances and Perspectives on Powder‐Based Halide Perovskite Film Processing

“…Upon contact with the substrate, the particles break up and form a nanocrystalline layer, which is further densified by subsequent particles due to a room temperature impact consolidation (RTIC) mechanism. [101] Details on the process can, e.g., be found in the reviews of Akedo [101] and Hanft et al [102] For an overview on investigated materials for sensing and energy applications, we refer to the review from Schubert et al [103] and for first commercial applications to the review by Akedo. [104] In a proof-of-concept study, we demonstrated the fabrication of perovskite thin films using PAD in 2016.…”