Solid oxide fuel cells (SOFCs) based on the proton conducting BaZr0.1Ce0.7Y0.2O3–δ (BZCY) electrolyte were prepared and tested in 500–700 °C using humidified H2 as fuel (100 cm3 min–1 with 3% H2O) and dry O2 (50 cm3 min–1) as oxidant. Thin NiO‐BZCY anode functional layers (AFL) with 0, 5, 10 and 15 wt.% carbon pore former were inserted between the NiO‐BZCY anode and BZCY electrolyte to enhance the cell performance. The anode/AFL/BZCY half cells were prepared by tape casting and co‐sintering (1,300 °C/8 h), while the Sm0.5Sr0.5CoO3–δ (SSC) cathodes were prepared by thermal spray deposition. Well adhered planar SOFCs were obtained and the test results indicated that the SOFC with an AFL containing 10 wt.% pore former content showed the best performance: area specific resistance as low as 0.39 Ω cm2 and peak power density as high as 0.863 W cm–2 were obtained at 700 °C. High open circuit voltages ranging from 1.00 to 1.12 V in 700–500 °C also indicated negligible leakage of fuel gas through the electrolyte.
The metal‐supported intermediate temperature solid oxide fuel cells with a porous nickel substrate, a nano‐structured LDC (Ce0.55La0.45O2–δ)–Ni composite anode, an LDC diffusion barrier layer, an LSGM (La0.8Sr0.2Ga0.8Mg0.2O3–δ) electrolyte, an LSCF (La0.58Sr0.4Co0.2Fe0.8O3–δ)–LSGM composite cathode interlayer and an LSCF cathode current collector are fabricated by atmospheric plasma spraying. Four different plasma spraying powers of 26, 28, 30, and 34 kW are used to fabricate the LSCF–LSGM composite cathode interlayers. Each cell with a prepared LSCF–LSGM composite cathode interlayer has been post‐heat treated at 960 °C for 2 h in air with an applied pressure of 450 g cm–2. The current‐voltage‐power and AC impedance measurements indicate that the LSCF–LSGM composite cathode interlayer formed at 28 kW plasma spraying power has the best power performance and the smallest polarization resistance at temperatures from 600 to 800 °C. The microstructure of the LSCF–LSGM composite cathode interlayer shows to be less dense and composed of smaller dense regions as the plasma spraying power decreases to 28 kW. The durability test of the cell with an optimized LSCF–LSGM composite cathode interlayer gives a degradation rate of 1.1% kh–1 at the 0.3 A cm–2 constant current density and 750 °C test temperature.
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