Sputtered, electroless, and rolled palladium–ceramic membranes

Three techniques were used to produce palladium–ceramic (Pd–ceramic) composite membranes for hydrogen separation and production. They are sputtering, electroless deposition and rolling of thin Pd alloy films over ceramic porous tubes. After studying and developing the three coating techniques, an extensive testing and characterizing work was carried out on these thin film composite membranes. The results show that in the sputtered (0.5–5 μm) and electroless (2.5–20 μm) composite membranes, the thermal cycling of the hydrogenated metallic layer produces membrane failures. Such failures are characterized by crack formation and metal film peeling. This fact has been explained by an evaluation of the shear stresses at the metal–ceramic interface due to the differential elongation between the palladium (Pd) coating and the ceramic support under thermal cycling and hydrogen loading. The rolled membranes (50–70 μm), however, because of the particular coating solution, have shown a complete hydrogen selectivity and good chemical and physical stability in long-term tests