Philosophiae Doctor - PhD / High Temperature Polymer Electrolyte Membrane Fuel Cells (HT-PEMFC) have received renewed interest in recent years due to its inherent advantages associated with the limitations faced by Low Temperature Polymer Electrolyte Membrane Fuel Cells (LT-PEMFC). The high Pt loadings required for PEMFCs have significantly hindered its commercialisation. Electrophoretic Deposition (EPD) is a promising route to reduce the noble metal loading. EPD is a method in which charged colloidal particles are deposited onto a target substrate under the force of an externally applied electric field. To effectively study the EPD method, the methodology of this study was divided into two parts: (i) the EPD method was studied via known empirical methods to fabricate, test and characterise MEAs suitable for HT-PEMFCs. The feasibility of the EPD method was determined by comparing the performance of the fabricated EPD MEAs to MEAs fabricated via spraying methods, and (ii) due to the promising results obtained in part (i) of the methodology, a theoretical model was developed to obtain a deep understanding about nature of the interactions between the Pt/C particles in a colloidal suspension. The theoretical model will serve as a foundation for future studies. In part (i) of the methodology, the Pt/C particles were studied in organic solutions (i.e. Isopropyl Alcohol, IPA) via the Zetasizer Nano ZS instrument under various salt (NaCl) concentrations and pH conditions while introducing polymeric surfactants, i.e. Nafion® ionomer and Polytetrafluoroethylene (PTFE) to the suspension. The optimum catalyst suspensions were selected to fabricate GDEs via the EPD method. Physical characterisations revealed that the EPD GDEs exhibited cracked morphology with high porosity. Electrochemical characterisations revealed that the EPD MEA showed significantly better performance (i.e. 73% higher peak power) compared to the hand vi sprayed MEA due to lower charge transfer and mass transport resistance at high current densities. Compared to the ultrasonically sprayed MEA, the EPD MEA exhibited a peak power increase of ~12% at a slightly lower Pt loading (i.e. ~4 wt%). A comparative study between the Nafion® ionomer and PTFE in the CLs of two EPD MEAs revealed superior performance for the EPD MEA with the PTFE in the CLs. Part (ii) of the methodology deals with the electrical interfacial properties of the aqueous Pt/C suspension. The study consists of two sets of measurements (i.e. electrophoretic and coagulation dynamic studies) conducted for different electrolyte compositions. A theoretical background on determining the interfacial potential and charge from electrophoretic and coagulation dynamic measurements are provided. Detailed statements of the Standard Electrokinetic and Derjaguin, Landau, Vervey and Overbeek Models are given in the forms that are capable of addressing electrophoresis and the interaction of particles for an arbitrary ratio of the particle to Debye radius, interfacial potential and electrolyte composition. The obtained experimental data were processed by using numerical algorithms based on the formulated models for obtaining the interfacial potential and charge. While analysing the dependencies of interfacial potential and charge on the electrolyte compositions charge, conclusions were made regarding the mechanisms of charge formation. It was established that the behaviour of system stability is in qualitative agreement with the results computed from the electrophoretic data. The verification of quantitative applicability of the employed models was conducted by calculating the Hamaker constant from the experimental data. It was proposed how to explain the observed variations of the predicted Hamaker constant and its unusually high value.

Electrophoretic deposition (EPD) has been used to produce the yttria-stabilized zirconia (YSZ) coatings on metal substrates. Sintering of YSZ with and without doping has been carried out at 1150 °C for 2hrs. The properties of these coatings have been examined in light of thermal barrier applications. For EPD, the green density increases with an initial increase in the HCl concentration and the EPD time. This suggests that particle packing was influenced by a time dependent re-arrangement, in addition to the initial suspension dispersion state. The green density peaks at a electrical conductivity of around 10×10-4 S/m achieved by an 0.5 mM HCl addition for the 20 g/l suspensions with the EPD time of around 8 ~10 minute. For sintered coatings, the HCl concentration had a marked effect on the neck size to grain size ratio of the 8 mol% yttria-stabilized zirconia (8YSZ) coatings. The presence of ZrCl4 and ZrOCl2, and a high concentration of oxygen vacancies at the grain boundaries are believed to promote neck growth in the early stage of sintering at 1150 °C. During sintering of 3 mol% and 8 mol% yttria-stabilized zirconia (3YSZ and 8YSZ) at 1150 ºC for 2hrs, the densification rate substantially increased with a small amount of Fe2O3 addition (0.5 mol%) to the 3YSZ/8YSZ deposits. A more pronounced graingrowth was present in the Fe2O3 doped 8YSZ deposits. The increased Zr4+ diffusion coefficient is mainly responsible to the rapid densification rate of the Fe2O3 doped 3YSZ/8YSZ deposits. A small grain growth observed in the Fe2O3 doped 3YSZ deposits is attributed to the Fe3+ segregation at grain boundary. A small amount of CeO2 doping was found to substantially inhibit the densification rate of the doped 3YSZ deposits with a minor grain growth. Fe2O3 doping reduced the thermal conductivities of 3YSZ/8YSZ. It is found that Rayleigh-type phonon scattering due to the mass difference alone is inadequate to explain the thermal conductivity of Fe2O3 doped YSZ systems. The lattice strain effects due to the ionic radius difference could more effectively reduce thermal conductivity of the Fe2O3-doped 3YSZ. A decrease in the growth rate of the TGO scale with the increasing Fe2O3 additions was observed for the oxidized FeCrAlY metal substrates with the Fe2O3-doped 3YSZ coating, which was found to be attributed to the early formation of the stable and dense α-Al2O3 phase due to the presence of Fe3+ ions.

<p>Electrochemical methods show great promise in the deposition of biocompatible coatings for biomedical applications with advanced functionality. Consequently, methods of creating coatings of bioactive materials, such as halloysite nanotubes (HNT), hydroxyapatite (HA), chitosan, hyaluronic acid (HYH), poly-L-ornithine (PLO) and poly-L-lysine (PLL) and polyacrylic acid (PAA) have been developed through the use of electrophoretic deposition (EPD). The co-deposition of these materials are achieved at voltages ranging from 5 to 20 V on a 304 stainless steel substrate using suspensions of 0.5 and 1.0 gL^-1 biopolymer (chitosan, PAA, PLO, PLL) containing 0.3, 0.5 0.6, 1.0 and 2.0 gL^-1 bioceramic (HNT, HA). The resulting films were then investigated to further understand the kinetics and mechanics of deposition, determine their properties, and evaluate their suitability for physiological applications. The films were studied using X-Ray Diffraction (XRD), Differential Thermal Analysis and Thermogravimetric Analysis (DTA/TGA), Scanning Electron Microscopy (SEM), Quartz Crystal Microbalance (QCM) and Linear Polarisation. The results indicate that film thickness, composition and morphology can be controlled and modified at will, and that the deposition of composite films, multilayer laminates and functionally graded films are possible.</p> / Master of Applied Science (MASc)