A method for joining a metal component to a ceramic component is presented. The method includes disposing a metallic barrier layer on a metallized portion of the ceramic component, and joining the metal component to the metallized portion of the ceramic component through the metallic barrier layer. The metallic barrier layer comprises nickel and a melting point depressant. The metallic barrier layer is disposed by a screen printing process, followed by sintering the layer at a temperature less than about 1000 degrees Celsius. A sealing structure including a joint between a ceramic component and a metal component is also presented.

Battery systems, and methods for manufacturing the same, are disclosed. The battery system may include one or more layers of anode, cathode, and electrolyte. The electrolyte may be solid, dense, and thin. The electrolyte may be configured in a non-planar geometry, such as a concentric cylindrical geometry or a helical geometry. A sealant may be applied to a housing enclosing the anode, cathode, and a portion of the electrolyte such that electrode-to-electrode contact is prevented. The method of manufacturing a battery system may include sonicating materials forming the electrolyte and curing the materials in layers. The anode and cathode materials are applied to the electrolyte and are enclosed in the housing. The sealant is applied such that contact is prohibited between the anode and the cathode.

A method for joining a ceramic component to a metallic component is described. At least one layer of molybdenum is applied to a surface of the ceramic component, by a high-velocity molybdenum wire spray technique. A layer of a nickel-based braze composition is then applied over the molybdenum layer. The braze composition and the ceramic and metallic components are then heated to a sufficient brazing temperature, so as to provide a braze joint between the components. The method can be used to seal an open region of a thermal battery, e.g., a sodium metal halide-based battery.