Radiation-thermal sintering of oxide and composite materials for hydrogen energy by electron beam: A review

The scaling of hydrogen technologies – from production and storage to utilization – is critically dependent on advanced manufacturing methods for key components such as catalytic reactors, permselective membranes, and electrochemical cells. The synthesis and processing of high-performance ceramic materials for these devices necessitates innovative sintering approaches. Radiation-thermal sintering (RTS) employing high-energy electron beams offers a viable alternative to conventional sintering methods, facilitating the expeditious fabrication of ceramics with tailored mechanical, morphological, structural, and transport properties. Although techniques such as spark plasma and microwave sintering have been the subject of extensive reviews, RTS remains comparatively under-explored. This review comprehensively examines the application of RTS for engineering functional ceramics – including perovskites, Ruddlesden–Popper phases, fluorites, garnets, and magnetoplumbites. These ceramics are essential for solid oxide cells, oxygen/hydrogen separation membranes, catalysts for fuel transformation into hydrogen and syngas, and other applications. The current understanding of how RTS influences material properties and device performance is demonstrated. Furthermore, critical research gaps are identified, particularly concerning the impact of electron irradiation on defect equilibria, ionic conductivity, and long-term functional stability. This underscores the necessity for focused studies to fully harness RTS for the fabrication of next-generation energy devices.