Development of over 3000 cycles durable macro-encapsulated aluminum with cavity by a sacrificial layer method for high temperature latent heat storage

The high-temperature metallic phase change materials (PCMs) are attracting great attentions as alternatives to sensible heat storage materials in thermal energy storage (TES) systems. However, the high corrosivity, easy leakage and oxidation phenomena of metallic PCMs have limited their applications. This work reports a facile and novel sacrificial layer method with the purpose to create macro-encapsulating aluminum (Al) PCM by alumina (Al2O3) shell characterized by a 'buffer' inner cavity. The inner cavity could offer buffer space to accommodate the huge thermal volume expansion of Al core PCM during heating and melting, thereby pre-venting the breakage of the capsules and ensuring the long-term stability. A series of Al balls with diameters of 4-25 mm were firstly coated with paraffin sacrificial layer then by Al2O3 dough shell, which was finally con-ducted by the two-step heat treatment, in which a low-temperature stage aimed at removing the paraffin layer while the high-temperature stage aimed at the capsule sintering formation. The final macrocapsules with di-ameters of 6.5-31.5 mm were obtained, in which the capsules with Al core balls larger than 15 mm showed superior gravimetric and volumetric heat storage density because of their high core-shell ratio. For example, the 25 mm@0.75 mm@2.5 mm macrocapsules could present high heat storage density of 348 kJ/kg and 902 J/cm3 at the temperature range of 600-700 degrees C. The macrocapsules also showed a long-time thermal cycling stability, since that no damage or leakage was observed over 3000 times of melting and solidification under air atmo-sphere, indicating that they can be used over 8 years without any degradation of thermophysical properties. This demonstrates the potential application of the Al2O3 encapsulated Al macrocapsules with inner cavity in high -temperature TES systems.

Automated summary

This work presents a facile and novel sacrificial layer method to create macro-encapsulating aluminum (Al) phase change materials (PCMs) by coating them with an alumina (Al2O3) shell characterized by a 'buffer' inner cavity. The macrocapsules showed high heat storage density and long-term thermal cycling stability, demonstrating their potential application in high-temperature thermal energy storage (TES) systems.