Atmospheric plasma spraying to fabricate metal‐supported solid oxide fuel cells with open‐channel porous metal support

Abstract

Metal‐supported solid oxide fuel cells (MS‐SOFCs) have been fabricated by applying phase‐inversion tape‐casting and atmospheric plasma spraying (APS). The effect of the binder amount of the phase‐inversion slurries on the microstructure development of the 430L stainless steel metal support was investigated. The pore structures, the viscosity of the slurry, porosity and permeability of the as‐prepared metal supports are significantly influenced by the amount of the binder. NiO–scandia‐stabilized zirconia (ScSZ) anode, ScSZ electrolyte and La0.6Sr0.4Co0.2Fe0.8O3−δ (LSCF) cathode layers were consecutively deposited on the metal support with an ideal microstructure by APS process. The effect of plasma power of the APS on the microstructure of the electrolyte and cathode was investigated. A dense electrolyte layer and a porous cathode layer were successfully obtained at 40 and 6 kW of the APS plasma power, respectively. MS‐SOFCs, with a cell configuration of 430L/Ni‐ScSZ/ScSZ/LSCF, achieved a maximum cell power density of 1079 mW cm−2 at 700°C using humidified H2 as fuel and ambient air as oxidant. The corresponding ohmic resistance and total resistance of MS‐SOFCs was 0.14 and 0.32 Ω cm2, respectively. This work demonstrates the feasibility of fabricating high‐performance MS‐SOFCs with economical and scalable techniques.

Overview of Approaches to Increase the Electrochemical Activity of Conventional Perovskite Air Electrodes

“…[174,180,216,217] (LSCF), spraying [212,[218][219][220][221] (LSM), Refs. [170,173,[222][223][224] (LSCF). Figure 5 shows schematics of these deposition methods.…”

“…Figure 5 shows schematics of these deposition methods. deposition in planar cells on the supporting fuel electrode, which are technologically simple and easily scalable, are slurry coating [198][199][200][201] (LSM), [202][203][204] (LSCF), screen printing [205,[206][207][208][209] (LSM), [110,158,183,210,211] (LSCF), tape casting [212][213][214][215] (LSM), [174,180,216,217] (LSCF), spraying [212,[218][219][220][221] (LSM), [170,173,[222][223][224] (LSCF). Figure 5 shows schematics of these deposition methods.…”

Unveiling the Promoted LSTM/YSZ Composite Anode for Direct Utilization of Hydrocarbon Fuels

“…x Mn x MoO 6-δ [43][44][45], strontium titanate-based perovskites such as (La,Sr)TiO 3-δ [46,47], and lanthanum chromate based perovskites like (La,Sr)(Cr,Mn)O 3-δ [38,48,49] have demonstrated promising characteristics for SOFC anodes. In particular, the La 0.4 Sr 0.6 Ti 1-x Mn x O 3 material has garnered attention as a high-potential anode material.…”

Hydrothermal Synthesis of Nickel Oxide and Its Application in the Additive Manufacturing of Planar Nanostructures

“…A further increase in the performance of SOFCs is not only possible by using intermediate-temperature functional layers but also by moving towards planar-type cells. To date, a wide range of methods are used to implement this problem: screen printing [ 40 , 41 , 42 ], tape casting [ 43 , 44 ], the infiltration method [ 45 , 46 ], spray pyrolysis [ 47 , 48 ], and sputtering methods [ 49 , 50 ]. Nevertheless, these approaches do not always allow for the achievement of the required lateral resolution, reproducibility of microstructural features, and desired area and geometry of the planar structures.…”