Design and optimization of components and processes for plasma sources in advanced material treatments

The research activities described in the present thesis have been oriented to the design and development of components and technological processes aimed at optimizing the performance of plasma sources in advanced in material treatments. Consumables components for high definition plasma arc cutting (PAC) torches were studied and developed. Experimental activities have in particular focussed on the modifications of the emissive insert with respect to the standard electrode configuration, which comprises a press fit hafnium insert in a copper body holder, to improve its durability. Based on a deep analysis of both the scientific and patent literature, different solutions were proposed and tested. First, the behaviour of Hf cathodes when operating at high current levels (250A) in oxidizing atmosphere has been experimentally investigated optimizing, with respect to expected service life, the initial shape of the electrode emissive surface. Moreover, the microstructural modifications of the Hf insert in PAC electrodes were experimentally investigated during first cycles, in order to understand those phenomena occurring on and under the Hf emissive surface and involved in the electrode erosion process. Thereafter, the research activity focussed on producing, characterizing and testing prototypes of composite inserts, combining powders of a high thermal conductibility (Cu, Ag) and high thermionic emissivity (Hf, Zr) materials The complexity of the thermal plasma torch environment required and integrated approach also involving physical modelling. Accordingly, a detailed line-by-line method was developed to compute the net emission coefficient of Ar plasmas at temperatures ranging from 3000 K to 25000 K and pressure ranging from 50 kPa to 200 kPa, for optically thin and partially autoabsorbed plasmas. Finally, prototypal electrodes were studied and realized for a newly developed plasma source, based on the plasma needle concept and devoted to the generation of atmospheric pressure non-thermal plasmas for biomedical applications.

Luminescent Ionic Transition-Metal Complexes for Light-Emitting Electrochemical Cells

The European Union set the ambitious target of reducing energy consumption by 20% within 2020. This goal demands a tremendous change in how we generate and consume energy and urgently calls for an aggressive policy on energy efficiency. Since 19% of the European electrical energy is used for lighting, considerable savings can be achieved with the development of novel and more efficient lighting systems. In this thesis, accomplished in the frame of the EU project CELLO, I report some selected goals we achieved attempting to develop highly efficient, flat, low cost and flexible light sources using Light-Emitting Electrochemical Cells (LECs), based on ionic cyclometalated iridium(III) complexes. After an extensive introduction about LECs and solid-state lighting in general, I focus on the research we carried out on cyclometalated iridium(III) complexes displaying deep-blue emission, which has turned out to be a rather challenging task. In order to demonstrate the wide versatility of this class of compounds, I also report a case in which some tailored iridium(III) complexes act as near-infrared (NIR) sources. In fact, standard NIR emitting devices are typically expensive and, also in this case, LECs could serve as low-cost alternatives in fields were NIR luminescence is crucial, such as telecommunications and bioimaging. Since LECs are based on only one active material, in the last chapter I stress the importance of an integrated approach toward the right selection of suitable emitters not only from the photophysical, but also from the point of view of material science. An iridium(III) complex, once in the device, is interacting with ionic liquids, metal cathodes, electric fields, etc. All these interactions should be taken in to account if Europe really wants to implement more efficient lighting paradigms, generating light beyond research labs.

Advanced lithium battery chemistries for sustainable transportation

The specific energy of lithium-ion batteries (LIBs) is today 200 Wh/kg, a value not sufficient to power fully electric vehicles with a driving range of 400 km which requires a battery pack of 90 kWh. To deliver such energy the battery weight should be higher than 400 kg and the corresponding increase of vehicle mass would narrow the driving range to 280 km. Two main strategies are pursued to improve the energy of the rechargeable lithium batteries up to the transportation targets. The first is the increase of LIBs working voltage by using high-voltage cathode materials. The second is the increase of battery capacity by the development of a cell chemistry where oxygen redox reaction (ORR) occurs at the cathode and metal lithium is the anode (Li/O2 battery). This PhD work is focused on the development of high-voltage safe cathodes for LIBs, and on the investigation of the feasibility of Li/O2 battery operating with ionic liquid(IL)-based electrolytes. The use of LiMn1-xFexPO4 as high-voltage cathode material is discussed. Synthesis and electrochemical tests of three different phosphates, more safe cathode materials than transition metal oxides, are reported. The feasibility of Li/O2 battery operating in IL-based electrolytes is also discussed. Three aspects have been investigated: basic aspects of ORR, synthesis and characterization of porous carbons as positive electrode materials and study of limiting factors to the electrode capacity and cycle-life. Regarding LIBs, the findings on LiMnPO4 prepared by soluble precursors demonstrate that a good performing Mn-based olivine is viable without the coexistence of iron. Regarding Li/O2 battery, the oxygen diffusion coefficient and concentration values in different ILs were obtained. This work highlighted that the O2 mass transport limits the Li/O2 capacity at high currents; it gave indications on how to increase battery capacity by using a flow-cell and a porous carbon as cathode.