Synthesis of Cobalt–Nickel Aluminate Spinels Using the Laser-Induced Thermionic Vacuum Arc Method and Thermal Annealing Processes

To obtain highly homogeneous cobalt–nickel aluminate spinels with small crystallite sizes, CoNiAl alloy thin films were primarily deposited using Laser-induced Thermionic Vacuum Arc (LTVA) as a versatile method for performing processing of multiple materials, such as alloy/composite thin films, at a nanometric scale. Following thermal annealing in air, the CoNiAl metallic thin films were transformed into ceramic oxidic (Co,Ni)Al2O4 with controlled composition and crystallinity suitable for thermal stability and chemical resistance devices. Structural analysis revealed the formation of (Co,Ni)Al2O4 from the amorphous CoNiAl alloys. The mean crystallite size of the spinels was around 15 nm. Thermal annealing induces a densification process, increasing the film thickness together with the migration process of the aluminum toward the surface of the samples. The sheet resistance changed drastically from 200–240 Ω/sq to more than 106 Ω/sq, revealing a step-by-step conversion of the metallic character of the thin film to a dielectric oxidic structure. These cermet materials can be used as inert anodes for the solid oxide fuel cells (SOFCs), which require not only high stability with respect to oxidizing gases such as oxygen, but also good electrical conductivity. These combination metal–ceramics are known as bi-layer anodes. By controlling the crystallite size and the interplay between the oxide/metal composite, a balance between stability and electrical conductivity can be achieved.