Research Papers

Cost-Effective Single Step Cofiring Process for Manufacturing Solid Oxide Fuel Cells Using HSC™ Anode

[+] Author and Article Information
Kyung Joong Yoon, Srikanth Gopalan, Uday B. Pal

Department of Manufacturing Engineering, Boston University, 15 Saint Mary’s Street, Brookline, MA 02446

Guosheng Ye

 BTU International, Inc., 23 Esquire Road, North Billerica, MA 01862

J. Fuel Cell Sci. Technol 7(2), 021010 (Jan 11, 2010) (5 pages) doi:10.1115/1.3177449 History: Received March 31, 2008; Revised December 12, 2008; Published January 11, 2010; Online January 11, 2010

The anode-supported planar solid oxide fuel cell (SOFC) was fabricated by a cost-effective single step cofiring process using high shear compaction (HSC)™ anode substrate. The HSC™ process is a novel ceramic tape fabrication technique, which offers advantages in low-cost and high-volume production of the anode substrates over the conventional tape forming processes. The cell was comprised of a porous HSC™ Ni+8mol% yttria-stabilized zirconia (YSZ) anode substrate, a porous Ni+YSZ anode barrier layer, a porous and fine-grained Ni+YSZ anode active layer, a dense YSZ electrolyte, a porous and fine-grained Ca-doped LaMnO3(LCM)+YSZ composite cathode active layer, and a porous LCM cathode current collector layer. The fabrication process involved wet powder spraying of the anode barrier layer over the HSC™ anode substrate followed by screen-printing of the remaining component layers. The cell was then cofired at 1340°C for 2 h. The microstructure and the open circuit voltage of the cell confirmed that the cell was crack-free and leak-tight. The cofired cell showed a stable and acceptable electrochemical performance at 800°C under humidified hydrogen (360%H2O) as fuel and air as oxidant. The anode active layer with finer and less porous microstructure increased the triple phase boundary length and improved cell performance under conditions that simulated higher fuel utilization. The material system and fabrication process presented in this work offers great advantage in low-cost and high-volume production of SOFCs, and it can be the basis for scale-up and successful commercialization of the SOFC technology.

Copyright © 2010 by American Society of Mechanical Engineers
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Figure 1

Schematic of the HSC™ tape formation process

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Figure 2

Thickness of the anode barrier layer versus the number of the sprayed layers

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Figure 3

Cracks of the electrolyte due to the rough surface of the anode barrier layer

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Figure 4

Cells with different thicknesses of the anode barrier layer

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Figure 5

Microstructure of the cofired cell

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Figure 6

I–V and power density data measured at 800°C, 750°C, and 700°C with humidified hydrogen (97% H2–3% H2O) as fuel and air as oxidant

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Figure 7

I–V and power density data measured with various compositions of humidified hydrogen (3–60% H2O) as fuel and air as oxidant at 800°C

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Figure 8

SEM image of the anode active layer and anode barrier layer



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