Low cost, colloidal deposition methods have been utilized to produce novel solid oxide fuel cell structures on metal alloy support electrodes. YSZ films were deposited on iron-chrome supports on top of a thin Ni/YSZ catalytic layer, and sintered at 1350°C, in a reducing atmosphere. Dense, 20 m YSZ electrolyte films were obtained on highly porous stainless steel substrates.These metal-supported fuel cells were tested at 800 and 900°C, achieving power densities of over 200 mW/cm 2 at 900°C, using platinum paste cathodes. The cells have shown excellent resistance to thermal cycling, and open up a new low cost path to SOFC commercialization.
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